20. Reassembly

Transmission Reassembly

NOTE:
- Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
- 6-speed model is shown, 5-speed model is similar.

1. Install the magnet (A) and the differential assembly (B).





2. Install the 28 mm spring washer (A) and the 28 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer.





3. Apply tape to the mainshaft splines (D) to protect the seal. Install the mainshaft and the countershaft (E) into the shift forks (F), and install them as an assembly.
4. Install the reverse shift fork.





5. Install the reverse idler gear (A) and the reverse gear shaft (B) by aligning the mark (C) with the reverse gear shaft hole (D).





6. 5-speed model: Install the reverse lock cam.





7. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil gutter plate (B), the oil guide plate M, and the 72 mm shim into the transmission housing (C).





8. Remove any dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent leakage.

NOTE: Do not assemble the housings if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.





9. Install the 14 x 20 mm dowel pins (A).





10. Set the tapered cone ring (B) as shown (5-speed model). Place the transmission housing over the clutch housing, being careful to line up the shafts.
11. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (C). Release the snap ring so it seats in the groove of the countershaft bearing.
12. Make sure the 72 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension (1) as installed: 3.3 - 6.0 mm (0.13 - 0.24 inch)
13. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the 32 mm sealing cap (D), and install it on the transmission housing.

NOTE: Do not install the 32 mm sealing cap if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.

14. Install the harness bracket (A) (6-speed model), the transmission hanger A (B), the transmission hanger B (C), and the 8 mm flange bolts, finger-tight.





15. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
8 x 1.25 mm 27 Nm (2.8 kgf-m, 20 ft. lbs.)





16. Remove any dirt and oil from the change lever cover sealing surface. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the sealing surface.

NOTE: Do not install the change lever cover if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.





17. Install the 8 x 14 mm dowel pins (A), the change lever assembly (B), and the clutch line clip bracket (C).





18. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the interlock bolt (D), and install it on the transmission housing.

NOTE: Do not install the interlock bolt if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.

19. 2002-2004 models: Install the drain plug (A), the filler plug (B), and the 10 mm flange bolt (C) with new washers.





20. 2005-2006 models: Install the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), the output shaft (countershaft) speed sensor (D), the plain washer (5-speed model) (E), and the new O-ring (F).





21. Install the detent bolts (A), the springs, and the steel balls with new washers.





22. Apply liquid gasket (P/N 08718-0001 or 08718-0002) to the threads of the back-up light switch (B), and install it on the transmission housing.

NOTE: Do not install the back-up light switch if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue and reapply the liquid gasket.

23. 2002-2004 models: Install the vehicle speed sensor (VSS) (A) and the O-ring (B).





24. 2005-2006 models: Install the 20 mm bolt (A) and the new 20 mm washer (B).