24. Transmission Reassembly
Transmission ReassemblyNOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces,
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. 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).
7. Remove any dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0002) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent oil leakage.
NOTE: Do not install components 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.
8. Install the 14 x 20 mm dowel pins (A).
9. Place the transmission housing over the clutch housing, being careful to line Lip the shafts.
10. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (B). Release the snap ring so it seats in the groove of the countershaft bearing.
11. Make sure the 52 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)
12. Apply liquid gasket (P/N 08718-0002) to the threads of the 32 mm sealing cap (C), and install it on the transmission housing.
13. Install the transmission hanger A, the transmission hanger B, the harness bracket (C), and the 8 mm flange bolts, finger-tight.
14. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
15. Remove any dirt and oil from the shift lever cover sealing surface. Apply liquid gasket (P/N 08718-0002) to the sealing surface.
NOTE: Do not install components 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.
16. Install the 8 x 14 mm dowel pins (B), change lever assembly (C), and harness bracket A.
17. Apply liquid gasket (P/N 08718-0002) to the threads of the interlock bolt (D), and install it on the transmission housing.
18. Install the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), the output shaft (countershaft) speed sensor (D), and the new O-ring (E).
19. Install the detent bolts (A), the springs, and steel balls with new washers.
20. Apply liquid gasket (P/N 08718-0002) to the threads of the back-up light switch (B), and install it in the transmission housing.
21. Install the 20 mm bolt (A) and new 20 mm washer (B).
