Manual Transaxle Disassembly

DISASSEMBLY




1. Remove the rear cover bolts and rear cover.




2. Remove the backup light switch, gasket and mounting bracket.




3. Remove the poppet plugs, poppet springs and poppet balls.




4. Remove the speedometer drive gear assembly.




5. Remove the spring pin using the special tool (09414-11000). (KM 201 only)

6. Removal of the lock nuts. (KM 201 only)




1. Unstake the lock nuts on the input and intermediate shafts.




2. Shift the transaxle into reverse using the control and select levers.




3. Install the special tool (09432-21101) onto the input shaft.
4. Screw a 10 mm (0.39 in.) bolt into a mounting hole on the clutch housing and attach a breaker bar to the special tool (09432-21101).
5. Remove the lock nut, while bracing the breaker bar again the bolt.




7. Remove the 5th speed synchronizer sleeve and 5th speed shift fork. (KM 201 only)
8. Remove the 5th speed synchronizer hub, synchronizer ring, 5th speed gear, needle bearing, bearing sleeve and roller bearing. (KM 201 only)
9. After removing the snap ring, remove the spacer and the roller bearing (KM2OO only).




10. Remove the intermediate gear using the special tool (09455-21000). (KM 201 only)




11. Remove the reverse idler gear shaft bolt and restriction ball assembly.




12. Remove the transaxle cover bolts (13 EA) and the transaxle cover.




13. Remove the differential oil seal and oil guide.




14. Remove the output shaft bearing outer race and spacer using the special tool (09455-32200).
15. Remove the input shaft roller bearing outer ring using the special tool (09432-21000).




16. Remove the reverse shift lever and the reverse shift shoe.




17. Remove the reverse gear shaft and the reverse gear.




18. Remove the spring pins using the special tool (09414-11000).

19. Disassembly of the shift rail and fork assembly.




1. Shift the 1st-2nd gear shift fork into 2nd gear.
2. Shift the 3rd-4th gear shift fork into 4th gear.
3. Pull out the 1st-2nd shift rail and fork assembly with the select lever pushed to 5th-reverse shift rail side.




4. Pull out the 3rd-4th/5th-reverse shift rail and fork assembly together with the select lever fully pushed into the 1st-2nd rail side.
5. After pulling out the 1st-2nd shift rail and fork assembly in the shift rail hole located in the clutch housing, remove the reverse rail assembly and then the 1st-2nd shift rail and fork assembly (KM200 only)




20. Remove the bearing retainer.




21. Lift up the input shaft assembly and remove the intermediate shaft assembly.




22. Remove the output shaft assembly and differential gear assembly.




23. Remove the output shaft bearing outer race and spacer using the special tool (09455-32200).




24. Remove the differential bearing oil seal.




25. Remove the input shaft oil seal.