Part 2

INSTALLATION
Shift Shaft Oil Seal





- Install new shift shaft oil seal until flush with case.
- Before installing, apply multi-purpose grease to seal lip.

FRONT CASE COVER
REMOVAL
Cover Oil Seal





- Drive out old seal from inside of front case cover.
- Be careful not to damage front case cover.

INSTALLATION
Cover Oil Seal





- Install new front case cover oil seal until it stops.
- Before installing, apply multi-purpose grease to seal lip.

BEARING RETAINER
REMOVAL
Oil Catcher





- Drive out oil catcher from inside of bearing retainer.
- Be careful not to damage bearing retainer.

INSTALLATION
Oil Catcher





- Install oil catcher until it stops.
- Be careful not to damage or distort oil catcher or bearing retainer.
- Before installing, apply multi-purpose grease to seal lip.

REAR CASE
REMOVAL
Rear Oil Seal





- Pull out rear oil seal.

INSTALLATION
Rear Oil Seal





- Install new rear oil seal until it stops.
- Before installing, apply multi-purpose grease to seal lip.

Air Breather





- Install as shown in illustration.

Locking sealant: Refer to Case Components.

SHIFT CONTROL COMPONENTS
INSPECTION





- Check contact surface and sliding surface for wear, scratches, projections or other faulty connections.

L & H Shift Rod & Fork





- Assemble as shown in illustration.
- Retaining pin is the same size as the one for 2-4 shift rod.

2-4 Shift Rod & Fork





- Assemble as shown in illustration.
- Retaining pins are the same size.





- Pay special attention to the direction of fork guide collar.

ASSEMBLY





1. Assemble front case.
a. Install main gear assembly by tapping lightly.





b. Apply sealant to the mating surface and bolts of front case cover and install it on front case.
- These ten bolts should be coated with sealant.
- Tightening torque
A: 16 - 21 Nm (1.6 - 2.1 kg.m, 12 - 15 ft. lbs.)
B: 19 - 24 Nm (1.9 - 2.4 kg.m, 14 - 17 ft. lbs.)
Sealant: Refer to Case Components.





c. Apply gear oil to needle bearing and install it into main gear.





d. Install counter gear assembly by tapping lightly.





e. Install cross shaft and inner shift lever.
- When replacing cross shaft, outer shift lever or lock pin of outer shift lever, replace them as a set.





f. Apply sealant to plug and install it into front case.

Sealant: Refer to Case Components.





g. Insert interlock plunger into front case.





h. Install L & H shift rod and fork assembly with coupling sleeve.





i. Install 2-4 shift rod.





j. Install switches, check balls, check springs and plugs.
- Apply sealant to switches and plugs.

Sealant: Refer to Case Components.





2. Select counter gear rear bearing shim.
a. Seat counter gear assembly.





b. Place J34291 -1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of center case and allow gauging cylinder to rest on top outer portion of counter gear rear bearing. Lock gauging cylinder in place.





c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder).





d. Place bridge, legs, gauging cylinder and gauging plunger onto machined surface of front case assembly, and allow gauging plunger to drop until it contacts counter gear rear bearing mating surface.





e. Lock gauging plunger in place and use feeler gauge to measure gap between gauging cylinder and gauging plunger.
f. Use measured distance and following chart to select correct shim.

Counter gear end play: 0 - 0.2 mm (0 - 0.008 inch)

Counter gear rear bearing shim: Refer to image.

g. Select counter gear rear bearing shim.





3. Place suitable shim on counter gear rear bearing with grease.
4. Apply ATF to each part in front case.





5. Assemble center case assembly.
a. Install [1][2]mainshaft on center case by tapping lightly.
- Apply ATF to [1][2]mainshaft front bearing.





b. Install bearing retainer.








c. Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case.





d. Install front drive shaft by tapping lightly.
- Make sure shafts are lined up in the case.





e. Apply ATF to needle bearings and install them into front drive sprocket.
- These needle bearings can be installed more easily if front drive sprocket is rotated while installing them.





f. Install 2-4 coupling sleeve with 2-4 shift fork.
- Pay special attention to direction of coupling sleeve.





g. Install clutch gear and [1][2]mainshaft rear bearing.
- Place wooden block under [1][2]mainshaft in order to protect mainshaft front bearing.





h. Install spacer.
i. Select snap ring with proper thickness and install it.

Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 inch)

Available snap ring for [1][2]mainshaft rear bearing: Refer to image.





j. Install steel ball, speedometer drive gear and retainer ring.
- Steel ball is the smallest of check balls for this unit.





k. Install low gear and its bearing to [1][2]mainshaft.
- Apply ATF to needle bearing.





l. Install L & H hub and snap ring to [1][2]mainshaft.
- Pay special attention to direction of L & H hub.





m. Measure end play of low gear.

Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 inch)





6. Apply sealant to mating surface and put center case assembly onto front case and tighten bolts.

Sealant: Refer to Case Components.





7. Install snap ring to 2-4 shift rod.





8. Install oil gutter and oil cover.
9. Apply ATF to each part in center case.





10. Apply sealant to mating surface and install rear case on center case.
11. Install 4WD switch.
- Apply sealant to thread of switch.

Sealant: Refer to Case Components.