Part 2

BEARING HUB
Replacement

NOTE: Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, replace it.

1. Remove the bearing from the bearing hub using a bearing separator and a press as shown.

2. Install the new bearing on the bearing hub using the special tool and a press as shown.

SECONDARY SHAFT
Disassembly / Inspection / Reassembly

NOTE:
^ Lubricate all parts with ATF during reassembly.
^ Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
^ Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the 0-rings.
^ Install the conical spring washer in the direction shown.

Inspection

NOTE: Lubricate all parts with ATF during assembly.

1. Assemble the parts below on the secondary shaft.

2. Measure the clearance between the 38 x 56.5 mm splined washer and cotters with a feeler gauge.

STANDARD: 0.07 - 0.15 mm (0.003 - 0.006 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

3. If the clearance is out of standard, remove the splined washer, and measure its thickness.

4. Select and install a new splined washer, then recheck.
5. After replacing the splined washer, make sure that the clearance is within standard.
6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft.

7. Assemble the parts below on the secondary shaft.

NOTE: Do not assemble the O-rings during inspection.

8. Set the dial indicator to the 2nd gear as shown.

9. Hold the 27 x 47 x 5 mm thrust washer against the clutch assembly, and measure the 2nd gear axial clearance while moving the 2nd gear.

STANDARD: 0.04 - 0.12 mm (0.002 - 0.005 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

10. If the clearance is out of standard, remove the 37 x 55 mm thrust shim and measure its thickness.

11. Select and install a new thrust shim, then recheck.
12. After replacing the thrust shim, make sure that the clearance is within standard.
13. Be sure to install the 27 x 47 x 5 mm thrust washer on the mainshaft.

SECONDARY SHAFT IDLER GEAR
Replacement

NOTE: Check the bearing for wear, damage, and rough movement. If the bearing is worn or damage, replace it.

1. Place the secondary shaft idler gear in a vise with soft jaws.

2. Remove the bearing from the secondary shaft idler gear using a bearing puller.

3. Install the new bearing on the secondary shaft idler gear using the special tool and a press as shown.

CLUTCH

Illustrated Index

Disassembly

1. Remove the snap ring, then remove the clutch end plate, clutch discs, and plates.

2. Remove the disc spring from the 3rd and 4th clutches.

3. Remove the waved washer spring from the 1st clutch.

4. Install the special tools as shown.

For 3rd and 4th clutch assembly

CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.

For 1st and 2nd clutch assembly

5. Compress the spring until the snap ring can be removed.

6. Remove the snap ring. Then remove the special tools, spring retainer, and return spring.

7. For 3rd and 4th clutch:
Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the piston. Place a finger tip on the other end while applying air pressure.

Reassembly

NOTE:
^ Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
^ Blow out all passages.
^ Lubricate all parts with ATF before assembly.

1. Inspect the check valve of the 3rd and 4th clutches; if it's loose, replace the piston.

2. Install new O-rings on the piston and the spring retainer (1st and 2nd clutches).

3. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing.

NOTE: Do not pinch the O-ring by installing the piston with too much force.

4. Install the return spring and spring retainer, and position the snap ring on the retainer.

5. Install the special tools as shown.

For 3rd and 4th clutch assembly

For 1st and 2nd clutch assembly

6. Compress the return spring with the special tools.

7. Install the snap ring.
8. Remove the special tools.

9. Install the disc spring in the 3rd, and 4th clutches in the direction shown.

10. Install the waved washer spring in the 1st clutch.
11. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes. Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt and other foreign matter.

12. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with the flat side toward the disc.

13. Install the snap ring.

14. Measure the clearance between the clutch end plate and top disc with a dial indicator. Zero the dial indicator with the clutch end plate lowered, and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

15. If the clearance is not within the service limits, select a new clutch end plate from the following table.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates.