Part 1

1. INSTALL SECOND GEAR
a. Apply gear oil to the output shaft.
b. Slide the 2nd gear and No. 1 synchronizer ring onto the output shaft.




2. ASSEMBLE NO.1 CLUTCH HUB AND HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




3. INSTALL NO.1 CLUTCH HUB ASSEMBLY
Using SST and a press, align the synchronizer ring slots with the shifting keys and press in the clutch hub.
SST 09515-30010




4. ASSEMBLE FIRST GEAR, NEEDLE ROLLER BEARING AND INNER RACE
Apply gear oil to the bearing.

5. INSTALL FIRST GEAR ASSEMBLY
a. Install the locking ball in the shaft.
b. Slide the No.1 synchronizer ring and 1st gear on the output shaft with the synchronizer ring slots aligned with the shifting keys, turn the inner race to align it with the locking ball.







c. Select a snap ring that will allow minimum axial play and install it on the shaft.




6. CHECK SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clearance.

Standard clearance: 0.150 - 0.250 mm (0.0059 - 0.0098 in.)




7. CHECK FIRST GEAR THRUST CLEARANCE
Using a dial indicator, measure the 1st gear thrust clearance.

Standard clearance: 0.150 - 0.275 mm (0.0059 - 0.0108 in.)




8. INSTALL THIRD GEAR
a. Apply gear oil to the output shaft.
b. Slide the 3rd gear and No.2 synchronizer ring onto the output shaft.




9. ASSEMBLE NO.2 CLUTCH HUB AND HUB SLEEVE
a. Install the key springs and shifting keys to the clutch hub.
b. Install the clutch hub to the hub sleeve.




10. INSTALL NO.2 CLUTCH HUB ASSEMBLY
Using SST and a press, align the synchronizer ring slots with the shifting keys and press in the clutch hub.
SST 09515-30010




11. INSTALL FOURTH GEAR
a. Apply gear oil to the output shaft.
b. Slide the large thrust bearing onto the output shaft.




c. Slide the No.2 synchronizer ring, needle roller bearing and 4th gear onto the output shaft.
Align the synchronizer ring slots with the shifting keys.




d. Slide the thrust washer onto the output shaft.
e. Using a plastic-faced hammer, tap in the snap ring.




12. INSTALL FOURTH GEAR SMALL THRUST BEARING AND SPACER
a. Stick the thrust bearing onto the spacer with MP grease.
b. Using SST and a press, press in the spacer.
SST 09612-22011




13. INSTALL OUTPUT SHAFT FRONT BEARING
a. Using SST and a press, press in the bearing.
SST 09612-22011







b. Select a snap ring that will allow minimum axial play and install it on the shaft.




14. CHECK THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance: 0.150 - 0.250 mm (0.0059 - 0.0098 in.)




15. CHECK FOURTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the 4th gear thrust clearance.

Standard clearance: 0.020 - 0.240 (0.0008 - 0.0094 in.)




16. INSTALL FIFTH GEAR
a. Using SST and a press, press in the 5th gear.
SST 09612-22011







b. Select a snap ring that will allow minimum axial play and install it on the shaft.




17. INSTALL SLEEVE YOKE
Using a press, press in the sleeve yoke.




18. MOUNT INTERMEDIATE PLATE IN VISE
Secure the protrusion on the lower part of the intermediate.




19. INSTALL OUTPUT SHAFT, COUNTER GEAR. IDLER GEAR AND REVERSE IDLER GEAR
a. Using a plastic-faced hammer, tap in the output shaft and counter gear together about halfway.




b. Align the idler gear with the notched portion of the reverse idler gear shaft.




c. Using a plastic-faced hammer, tap in the idler gear shaft bearing about halfway.

CAUTION: Insure that the idler gear and output shaft spacer do not contact each other.




d. Using a plastic-faced hammer, tap each gear shaft until the bearing is in as far as it will go.




e. Using snap ring pliers, install the two snap rings.




f. Install the output shaft front bearing retainer and release arm plate with the four bolts.
Torque the bolts.

Torque: 130 kg-cm (9 ft-lb, 13 N.m)




20. INSTALL COUNTER FIFTH GEAR
a. Apply geal oil to the shaft of the counter gear.
b. Install the locking ball in the shaft.
c. Slide the thrust washer onto the output shaft. Align the locking ball groove of the thrust washer with the locking ball.
d. Slide the needle roller bearing, counter 5th gear and No.3 synchronizer ring.




21. ASSEMBLE NO.3 CLUTCH HUB AND HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




22. INSTALL NO.3 CLUTCH HUB ASSEMBLY
a. Using SST and a press, align the synchronizer ring slots with the shifting keys and press in the clutch hub.
SST 09612-22011







b. Select a snap ring that will allow minimum axial play and install it on the shaft.




23. CHECK COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 5th gear thrust clearance.

Standard clearance: 0.150 - 0.325 mm (0.0059 - 0.0128 in.)




24. INSTALL SHIFTING KEY RETAINER FOR FIFTH GEAR
a. Align the claws of the key retainer with the key groove of the clutch hub.
b. Install the key retainer with the snap ring.




25. INSTALL SHIFT FORKS, SHIFT ARM AND SHIFT FORK SHAFTS
a. Assemble the reverse shift arm and shift head with the E-ring.




b. Assemble No.3 shift fork.
1. Install the shift fork guide bushing and compression spring.
2. Install the spacer and compression spring.




3. Using a screwdriver and hammer, tap in the snap ring.




c. Install No.1 shift fork, reverse shift fork, No.1 shift fork shaft and release head (Z54F).
1. Align No. 1 shift fork with No. 1 hub sleeve groove.
2. Align the reverse shift fork with the reverse gear groove.




d. Install No. 2 shift fork, No. 2 shift fork shaft and release head. Align No.2 shift fork with No.2 hub sleeve groove.




e. Using SST, remove the screw plug (for interlock pin).
SST 09313-30021




f. Align the interlock pin groove of No.1 shift fork shaft with the interlock pin hole of No.2 shift fork shaft.
1. Place No.1 and No.2 hub sleeve in the neutral position.
2. Align the mount bolt holes of No. 1 shift fork and No.1 shift fork shaft.
3. Align the mount bolt holes of No.2 shift fork and No.2 shift fork shaft.




g. Install the three interlock pins.
Coat MP grease to the interlock pin.




h. Install the reverse shift arm, No.3 shift fork and No.3 shift fork shaft.
1. Connect the reverse shift arm and reverse shift fork.
2. Align No.3 shift fork with No. 3 hub sleeve groove.




i. Apply liquid sealer on the threads and under the screw plug head.
Sealant: Part No 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
j. Using SST, install and torque the screw plug.
SST 09313-30021

Torque: 220 kg-cm (16 ft-lb, 22 N.m)




k. Using a pin punch and hammer, tap in the slotted spring pin (for the reverse shift head).




i. Using a pin punch and hammer, tap in the slotted spring pins (for No.3 shift fork and release heads).




m. Install and torque the shift fork mount bolts.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)




n. Install the detent ball and spring into the reverse shift fork hole.
o. Using SST, install and torque the screw plug.
SST 09313-30021

Torque: 220 kg-cm (16 ft-lb, 22 N.m)

26. DISMOUNT INTERMEDIATE PLATE FROM VISE