Mainshaft: Service and Repair

DISASSEMBLE

Fork Assembly:

1. Remove shift fork assembly from mainshaft, then position shift fork assembly.
2. Disassemble 1-2 shift fork and interlock sleeve, then the 3-4 shift fork and interlock sleeve from shaft.

Input Gear Shaft Bearing Removal:

3. Remove input gear shaft front, rear and main bearings by pressing off shaft with bearing puller attachment tool No. D84L-1123-A, or equivalent.
4. Remove third and fourth gears and clutch hub from mainshaft by pressing shaft out.
5. Install bearing puller attachment tool No. D84L-1123-A, or equivalent, onto third gear, positioning lips of tool between two sets of teeth.
6. Install shaft protector tool No. D80L-625-3, or equivalent, on end of main shaft.

Mainshaft Disassembly:

7. Support first gear of main shaft on press bed as shown.
8. Use shaft protector tool No. D80L-625-3, or equivalent, to press main shaft through hub and first gear. Hold shaft with one hand to prevent it from falling.

ASSEMBLE

NOTE: During assembly, check the thrust clearances of each gear. Prior to assembly, thoroughly clean all parts and inspect their condition. Lightly oil gear bores and other parts with clean transaxle fluid.

Gear And Mainshaft Assembly:

Follow numeric sequence for General assembly procedures.