Part 1
CASE COMPONENTS
GEAR COMPONENTS
SHIFT CONTROL COMPONENTS
DISASSEMBLY
1. Remove nut of companion flange.
2. Remove companion flange.
3. Remove 4WD switch.
4. Remove rear case.
- Be careful not to damage the mating surface.
5. Remove oil cover and oil gutter.
6. Remove snap ring and retainer ring from 2-4 shift rod.
7. Remove bolts securing bearing retainer.
- This step is necessary to remove [1][2]mainshaft from center case.
8. Remove bolts securing center case to front case and then separate center case and front case.
9. Measure end play of low gear.
Standard: 0.2 - 0.35 Nm (0.0079 - 0.0138 inch)
- If end play is beyond the maximum value, check low gear and L & H hub for wear.
10. Disassemble center case assembly.
a. Remove snap ring from [1][2]mainshaft.
b. Pull out low gear with L & H hub.
c. Remove needle bearing of low gear.
d. Make sure of the direction of the drive chain before removing it. (It must be reinstalled in the same direction.)
e. Remove [1][2]mainshaft, front drive and drive chain as a set by tapping front end of mainshaft and front drive shaft alternately.
- Be careful not to bend drive chain.
11. Disassemble front case assembly.
a. Remove switch, plugs, check springs and check balls.
b. Remove outer shift lever.
c. Remove lock pin of inner shift lever and drive out cross shaft with plug.
d. Remove 2-4 shift rod.
e. Remove L & H shift rod and fork assembly with coupling sleeve.
f. Remove needle bearing from main gear.
g. Remove bolts securing front case cover and then remove case.
h. Remove counter gear by tapping lightly.
i. Remove main gear by tapping lightly.
REPAIR FOR COMPONENT PARTS
[1][2]MAINSHAFT
DISASSEMBLY
Check end play of front drive sprocket.
Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 inch)
- If end play is beyond the maximum value, check front drive sprocket and clutch gear for wear.
2. Remove retainer ring, speedometer drive gear and steel ball.
- Be careful not to lose the steel ball.
3. Remove snap ring and spacer.
4. Press out front drive sprocket with [1][2]mainshaft rear bearing and clutch gear together.
5. Remove needle bearing.
6. Remove bearing retainer and then remove snap ring.
7. Press out [1][2]mainshaft front bearing from mainshaft.
INSPECTION
Gear And Shaft
- Check gears for excessive wear, chips or cracks.
- Check shaft for cracks, wear or bending.
- Check coupling sleeve for wear or damage.
Bearing
- Make sure bearings roll freely and are free from noise, crack, pitting or wear.
ASSEMBLY
1. Press [1][2]mainshaft front bearing onto mainshaft.
- Pay special attention to its direction.
2. 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 front bearing: Refer to image.
3. Regarding to further procedures, refer to Assembly.
FRONT DRIVE SHAFT
DISASSEMBLY
- Front drive shaft front bearing and rear bearing
INSPECTION
Sprocket and Shaft
- Check sprocket for excessive wear, chips or cracks.
- Check shaft for cracks or wear.
Bearing
- Make sure bearings roll freely and are free from noise, crack, pitting or wear.
ASSEMBLY
- Press front drive shaft front bearing and rear bearing.
COUNTER GEAR
DISASSEMBLY
1. Press out counter gear front bearing.
- Remove front sub-gear, spacer and dish plate (M/T model only).
2. Press out counter gear rear bearing.
- Remove rear sub-gear, spacer and dish plate (M/T model only).
INSPECTION
Gear and Shaft
- Check gears for excessive wear, chips or cracks.
- Check shaft for cracks or wear.
Bearing
- Make sure bearings roll freely and are free from noise, crack, pitting or wear.
ASSEMBLY
1. Install front sub-gear, dish plate and spacer (M/T model only).
- Press on counter gear front bearing.
2. Install rear sub-gear, dish plate and spacer.
- Press on counter gear rear bearing (M/T model only).
MAIN GEAR
DISASSEMBLY
Main Gear Bearing
1. Remove snap ring.
2. Pull out main gear bearing.
Plug
- Always replace it with new one whenever it is removed.
INSPECTION
Gear and Shaft
- Check gears for excessive wear, chips or cracks.
- Check shaft for cracks or wear.
Bearing
- Make sure bearings roll freely and are free from noise, crack, pitting or wear.
ASSEMBLY
Main Gear Bearing
1. Press on main gear bearing.
2. 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 main gear bearing: Refer to image.
Plug
- Apply sealant to plug and install it.
Sealant: Refer to Gear Components.
FRONT CASE
REMOVAL
Shift Shaft Oil Seal
- Use a screwdriver to pry out old seal.
- Be careful not to damage case.
- Always replace with a new one whenever it has been removed.