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HOUSING COMPONENTS ASSEMBLY
id051100010200
1. Assemble in the order shown in the figure.
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1
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Extension housing
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2
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Roll pin
(See Roll Pin Assembly Note.)
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3
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Control case
(See Control Case Assembly Note.)
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4
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Transmission case
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5
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Main drive gear bearing
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6
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Snap ring
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7
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Oil seal (front)
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8
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Adjustment shim
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9
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Front cover
(See Front Cover Assembly Note.)
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10
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Clutch release collar
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11
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Clutch release fork
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12
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Boot
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13
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Neutral switch No.1
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14
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Neutral switch No.2 (with i-stop)
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15
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Plug (without i-stop)
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16
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Back-up light switch
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17
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Oil seal (rear)
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18
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Stud bolt
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19
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Dynamic damper
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Extension Housing Assembly Note
1. Apply silicone sealant TB1217E to the extension housing as shown in the figure.
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2. Assemble the extension housing.
Roll Pin Assembly Note
1. Assemble a new roll pin using a pin punch and a hammer.
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Control Case Assembly Note
1. Apply silicone sealant TB1217E to the control case as shown in the figure.
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2. Assemble the control case.
Transmission Case Assembly Note
1. Apply silicone sealant TB1217E to the transmission case as shown in the figure.
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2. Assemble the transmission case.
Main Drive Gear Bearing Assembly Note
1. Assemble the main drive gear bearing using the SSTs and a hammer.
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Oil Seal (Front) Assembly Note
1. Assemble the oil seal (front) using the SST and the press.
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Adjustment Shim Assembly Note
1. Measure dimensions A and B shown in the figure.
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2. Subtract dimension A from dimension B and calculate the bearing end play.
3. Select an adjustment shim so that the bearing end play is within the standard.
Adjustment shims for bearing end play adjustment
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Thickness (mm {in}) |
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0.30 {0.012}
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0.35 {0.014}
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0.40 {0.016}
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0.45 {0.018}
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0.50 {0.020}
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0.55 {0.022}
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0.60 {0.024}
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0.65 {0.026}
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0.70 {0.028}
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0.75 {0.030}
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0.80 {0.032}
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0.85 {0.034}
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0.90 {0.036}
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0.95 {0.038}
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1.00 {0.040}
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Front Cover Assembly Note
1. Apply lithium grease to the position of the front cover shown in the figure.
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2. Apply silicone sealant TB1217E to the front cover as shown in the figure.
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3. Assemble the front cover.
Oil Seal (Rear) Assembly Note
1. Using the SST and a hammer, assemble the oil seal (rear).
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