Part 3

TRANSFER ASSEMBLY


Disassembly and Assembly (continued)

15. Apply ATF to the new D-rings, and install them to the clutch piston.

CAUTION:
Do not reuse D-rings.





16. Install the thrust needle bearing race to the clutch piston.





17. Install the clutch piston to the center case as shown.

CAUTION:
Install so the fitting protrusion of clutch piston aligns with the dent of center case.





18. Remove all the sealant from the oil pressure check port and inside the center case.

CAUTION:
Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
19. Thread the new oil pressure check plug in 1 or 2 pitches and apply sealant to the oil pressure check plug threads. Tighten to the specified torque. Overhaul.
- Use Genuine Silicone RTV or equivalent. Fluid Type Specifications.

CAUTION:
Do not reuse oil pressure check plug.





20. Install the new snap ring to the clutch hub using suitable tool.

CAUTION:
Do not reuse snap ring.





21. Apply petroleum jelly to the needle bearing, and install the needle bearing, spacer, clutch drum and clutch hub to the mainshaft.





22. Install the new snap ring to the mainshaft.

CAUTION:
Do not reuse snap rings.





23. Apply ATF each plate, then install them into the clutch drum as shown.





24. Install the return spring assembly into the clutch hub.





25. Install the press flange by aligning the notches to the clutch hub as shown.





26. Press the press flange to install the new snap ring into snap ring groove on mainshaft using Tools.

Tool number
A: ST22452000 (J-34335)
B: ST30911000 ( - )
C: KV31103300 ( - )


CAUTION:
Do not reuse snap ring.





27. Install the new snap ring to the mainshaft using suitable tool.

CAUTION:
Do not reuse snap ring.





28. Apply ATF to the thrust needle bearing and install it on the press flange.





29. Install the new snap ring to the main shaft.

CAUTION:
Do not reuse snap ring.





30. Install the mainshaft rear bearing to the center case using Tool.

Tool number : ST15310000 (J-25640-B)






31. Install the mainshaft assembly using a press.
- Press the mainshaft into the center case using Tools.

Tool number
A: ST30911000 ( - )
B: ST33052000 ( - )





32. Install the C-rings to the mainshaft.





33. Set the washer holder on the mainshaft, and secure it with a new snap ring.

CAUTION:
Do not reuse snap ring.





34. Apply petroleum jelly to the stem bleeder and install it to the center case.





35. Apply ATF to the new seal ring and install it to the main oil pump cover.

CAUTION:
Do not reuse seal ring.





36. Install the inner gear and outer gear in the main oil pump housing. Then, measure the side clearance. Inspection and Adjustment.





37. Install the main oil pump housing, outer gear and inner gear to the center case.





38. Install the main oil pump cover to the center case, and tighten to the specified torque. Overhaul.





39. Remove all the sealant from the switch location area and inside the center case.

CAUTION:
Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
40. Thread the ATP switch and neutral-4LO switch in one to two pitches and apply sealant to the threads of the switches. Tighten to the specified torque. Overhaul.
- Use Genuine Silicone RTV or equivalent. Fluid Type Specifications,
"Recommended Chemical Products and Sealants".

NOTE:
- Neutral-4LO switch harness connector is gray.
- ATP switch harness connector is black.





41. Install the front drive shaft rear bearing using Tools.

Tool number
A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)






42. Install the front drive shaft to the front bearing using Tools.

Tool number
A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)






43. Install the drive chain to the front drive shaft and clutch drum.

CAUTION:
Install drive chain by aligning identification marks to the rear as shown.





44. Tap the front drive shaft while keeping it upright and press-fit the front drive shaft rear bearing.

CAUTION:
Do not tap drive chain.
45. Install the front case assembly. Overhaul.
46. Install the rear case assembly. Overhaul.

Front Case





1. Install the carrier bearing to the sun gear using Tools.

Tool number
A: ST30911000 ( - )
B: KV31103300 ( - )






2. Install the new snap ring to the sun gear assembly using suitable tool.

CAUTION:
Do not reuse snap ring.





3. Apply ATF to the circumference of the new metal bushing and install it to the sun gear assembly using Tool.

Tool number : ST35300000 ( - )

Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in)


CAUTION:
- Do not reuse metal bushing.
- Apply ATF to metal bushing before installing.





4. Apply ATF to the new needle bearing and install it to the sun gear assembly using Tool.

Tool number : ST33220000 ( - )

Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in)


CAUTION:
- Do not reuse needle bearing.
- Apply ATF to needle bearing before installing.





5. Install the sun gear assembly to the planetary carrier assembly.





6. Install the new snap ring to the planetary carrier assembly.

CAUTION:
Do not reuse snap ring.





7. Set the input bearing into the front case and install using Tool.

Tool number : ST30720000 (J-25405)






8. Install the new snap ring into the front case.

CAUTION:
Do not reuse snap ring.





9. Install the internal gear with its groove facing the snap ring into the front case. Then secure it with the new snap ring.

CAUTION:
Do not reuse snap ring.





10. Install the new front oil seal until it is seated flush with the end face of the front case using Tool.

Tool number : KV38100500 ( - )


CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal lip before installing.





11. Install the planetary carrier assembly and sun gear assembly to the front case using Tool.

Tool number : ST33200000 (J-26082)






12. Install the new snap ring to the sun gear.

CAUTION:
Do not reuse snap ring.





13. Apply petroleum jelly to the circumference of the new oil seal, and install it to the front case using Tools.

Tool number
A: ST30720000 (J-25405)
B: ST33200000 (J-26082)

Dimension : 4.0 - 4.6 mm (0.157 - 0.181 mm)


CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.





14. Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with new retaining pins.

CAUTION:
Do not reuse retaining pins.





15. Install the 2-4 sleeve and L-H sleeve to each fork.
16. Install the shift cross to the front case.





17. While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly (A) to the front case.





18. Apply liquid gasket to the entire center case mating surface of the front case assembly as shown.
- Use Genuine Anaerobic Liquid Gasket or equivalent. Fluid Type Specifications.

CAUTION:
Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.





19. Install the center case assembly to the front case assembly.

CAUTION:
Do not damage mainshaft end.
20. Tap the center case lightly and press-fit the front drive shaft bearing into the front case.





21. Tighten the front case bolts to the specified torque. Overhaul.

CAUTION:
Be sure to install air breather hose clamp, connector bracket and harness clip.
22. Install the drain plug with a new gasket.

CAUTION:
Do not reuse gasket.





23. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.





24. Install a new companion flange self-lock nut. Tighten to the specified torque using suitable tool. Overhaul.

CAUTION:
Do not reuse self-lock nut.





25. Remove all the sealant from the check plug, switch mounting and front case.

CAUTION:
Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
26. Install the check ball and check spring to the front case. Apply sealant to the check plug and wait detection switch and install them to the front case. Tighten to the specified torque. Overhaul.
- Use Genuine Silicone RTV or equivalent. Fluid Type Specifications,
"Recommended Chemical Products and Sealants".

NOTE:
Wait detection switch harness connector is black.





27. Install the new oil seal in the front case using Tool.

Tool number : ST22360002 (J-25679-01)


CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to seal lip before installing.
28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified torque. Overhaul.

Rear Case





1. Apply petroleum jelly to the circumference of the new rear oil seal. Install the new rear oil seal so that it is flush with the case tip face using Tool.

Tool number : ST30720000 (J-25405)


CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to seal lip before installing.





2. Apply petroleum jelly to the circumference of the new dust cover
(1). Position the new dust cover with protrusions (A) as shown.
- Rear case (2)

CAUTION:
- Do not reuse dust cover.
- Position the projection in the position as shown.





3. Install the new dust cover using Tool.

Tool number : KV40105310 ( - )

4. Install the air breather into the rear case.
5. Remove all the sealant from the rear case to center case mating surfaces.

CAUTION:
Remove all foreign materials such as water, oil, and grease from center case and rear case mating surfaces.
6. Apply liquid gasket to the entire rear case mating surface of the center case.
- Use Genuine Anaerobic Liquid Gasket or equivalent. Fluid Type Specifications.

CAUTION:
Do not to allow Liquid Gasket to enter stem bleeder hole.





7. Install the rear case to the center case. Tighten the bolts to the specified torque. Overhaul.