Disassembly

DISASSEMBLY

1. Remove companion flange nut.
2. Remove companion flange.

3. Remove 4WD switch.
4. Remove rear case.
- Be careful not to damage the mating surface.

5. Remove oil cover and oil gutter.
6. Remove snap ring from 2-4 shift rod.

7. Using calipers, measure the difference between front drive sprocket and 2-4 coupling sleeve as outlined under Measuring method below. If it is outside specifications, check front drive sprocket, 2-4 coupling sleeve, clutch gear, 2-4 shift fork and 2-4 fork rod for abnormalities. Replace faulty part(s) as required.
Measuring method
a. Move coupling sleeve until it is in contact with sprocket, then measure dimension A. Move coupling sleeve until it is in contact with clutch gear, then measure dimension B. Obtain dimensional difference C between two measurements A and B.
C = A - B
b. To determine dimension A, measure at 3 or 4 different points by rotating sprocket and obtain average value of 3 or 4 measurements.
Specification C: Refer to Specifications.

8. Remove bolts securing bearing retainer.
- This step is necessary to remove mainshaft from center case.

9. Remove bolts securing center case to front case, then separate center case from front case.

10. Measure low gear end play.
Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 inch)
- If end play is not within specification, check low gear and L & H hub for wear.
11. Disassemble center case assembly.

a. Remove snap ring from mainshaft.

b. Remove low gear with L & H hub.

c. Remove needle bearing from main shaft.

d. Make sure of the direction of the drive chain before removing it. (it must be reinstalled in the same direction.)

e. Remove mainshaft, front drive and drive chain as a set by tapping front end of mainshaft and front drive shaft alternately.
- Be careful not to bend drive chain.
12. Disassemble front case assembly.