Transmission

1. Install the differential assembly in the clutch housing.




2. Install the spring washer and washer with the angle against the clutch housing as shown.
3. Insert the mainshaft and countershaft into the shift forks and install them as an assembly.

NOTE: Before installing the mainshaft and countershaft assemblies, tape the mainshaft splines to protect them.




4. Install the reverse idler gear and reverse idler gear shaft in the clutch housing.




5. Install the reverse shift fork in the clutch housing with the 5th/reverse shift piece pin positioned in the slot of the reverse shift fork.

NOTE:
- Check that the steel ball is in the proper position.
- Select the thrust shim. Mainshaft Thrust Shim




6. Install the oil guide plate and thrust shim into the transmission housing.




7. Install the oil gutter plate in the transmission housing.

NOTE: Bend the hook of the oil gutter plate into the hole on the transmission housing.

8. Install the 28 mm sealing bolt.

NOTE: Apply liquid gasket (P/N 08718-0001) to the threads.




9. Apply liquid gasket to the clutch housing mating surface as shown.

NOTE:
- Use liquid gasket (P/N 08718-0001).
- Remove the dirt oil from the sealing surface.
- Seal the entire circumference of the bolt hole to prevent oil leakage.
- If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings and allow it to cure at least 30 minutes after assembly before filling transmission with oil.

10. Install the 14 x 20 mm dowel pins.




11. Set the stopper ring as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.

NOTE: Align the long arm of 5th shift fork with the hook on the stopper ring.




12. Lower the transmission housing with the snap ring pliers and set the snap ring in the groove of the countershaft bearing.
13. Check that the snap ring is securely seated in the groove of the countershaft bearing.

Dimension A as installed: 3.60-6.32 mm (0.142-0.249 in)




14. Install the 32 mm sealing bolt.

NOTE: Apply liquid gasket (P/N 08718-0001) to the threads.




15. Torque the bolts in a crisscross pattern in several steps as shown.




16. Install the reverse idler gear shaft bolt.
17. Install the steel balls, springs, washers and setting screws.
18. Install the shift arm cover assembly. Shift Arm Assembly
19. Shift the transmission through all the gears before installing it.