Overhaul (Disassembly)

Disassembly





1. Remove companion flange nut and companion flange using Tool, as shown.





2. Remove 4WD switch.
3. Remove rear case using screwdriver or suitable tool, as shown.
^ Be careful not to damage the mating surface.





4. Remove oil cover and oil gutter.
5. Remove snap ring and retainer ring from 2-4 shift rod.
6. Using calipers, measure the difference between front drive sprocket and 2-4 coupling sleeve as outlined under measuring method below. If it is outside specifications, check front drive sprocket, 2-4 coupling sleeve, clutch gear, 2-4 shift fork and 24 fork rod for abnormalities. Replace faulty part(s) as required.
Measuring method:





a. Move Coupling sleeve until it is in contact with sprocket, then measure dimension A. Move coupling sleeve until it is in contact with clutch gear, then measure dimension B. Obtain dimension difference C between two measurements A and B.
b. A-B = C
c. To determine dimension A, measure at 3 or 4 different points by rotating sprocket and obtain average value of 3 or 4 measurements.
d. Specification C: refer to "CLEARANCE BETWEEN FRONT DRIVE SPROCKET AND 2-4 COUPLING SLEEVE".





7. Remove bolts securing bearing retainer.
^ This step is necessary to remove mainshaft from center case.





8. Remove bolts securing center case to front case and then separate center case and front case using screwdriver or suitable tool, as shown.
^ Be careful not to damage the mating surface.





9. Measure low gear end play.
Low gear end play: 0.2 - 0.35 mm (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 mainshaft.





b. Pull out low gear with L & H hub using Tool, as shown.





c. Remove needle bearing from mainshaft.





d. Make sure of the direction of the drive chain before removing it.
It must be reinstalled in the same direction.





e. Remove mainshaft, front drive and drive chain as a set by tapping front end of mainshaft and front drive shaft alternately using a soft hammer, as shown.

CAUTION: Be careful not to bend drive chain.

11. Disassemble front case assembly.





a. Remove transfer neutral position switch, plugs, check springs and check balls.





b. Remove lock pin from outer shift lever using a drift or suitable tool, as shown. Then remove outer shift lever.





c. Remove lock pin of inner shift lever and drive out cross shaft with plug using a soft hammer, as shown.





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 using screwdriver or suitable tool.
^ Be careful not to damage the mating surface.





h. Remove counter gear by tapping lightly using a soft hammer, as shown.





i. Remove main gear by tapping lightly using a soft hammer, as shown.