Disassembly of Transmission

DISASSEMBLY OF TRANSMISSION



1. REMOVE RELEASE FORK, BEARING, BACK-UP LIGHT SWITCH AND SPEEDOMETER DRIVEN GEAR
2. REMOVE RELEASE BEARING RETAINER
3. REMOVE TRANSMISSION CASE COVER
4. REMOVE NO.3 SHIFT FORK SECURING BOLT




5. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Maximum clearance: 0.45 mm (0.0177 in.)




6. REMOVE NO.1 AND NO.2 LOCK BALL ASSEMBLIES
a. Loosen the lock nut and remove the No.1 lock ball.




b. Using SST and remove the No.2 lock ball.
SST 09313-30021
7. REMOVE SELECTING BELLCRANK




8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY




9. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the nut.
b. Engage the gear double meshing.




c. Remove the lock nut.
HINT: The lock nut has LH threads.

d. Disengage the gear double meshing.




10. REMOVE NO.3 HUB SLEEVE ASSEMBLY AND SHIFT FORK
a. Using two screwdrivers and a hammer, tap out the snap ring.
b. Remove the shifting key retainer.




c. Using the three case cover set bolts, tighten the three bolts a little at a time and remove No.3 hub sleeve assembly and shift fork.
11. REMOVE FIFTH GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS AND SPACER




12. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-20017




13. REMOVE REAR BEARING RETAINER
14. REMOVE BEARING SNAP RINGS
Using snap ring pliers, remove the two snap rings.




15. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT




16. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM




17. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a plastic hammer.




18. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into reverse.
b. Remove the two bolts and pull off the reverse shift arm.
19. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft.




20. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, INPUT SHAFT AND OUTPUT SHAFT.
a. Drive out the slotted spring pin from No.1 fork shaft.




b. Remove the input shaft and output shaft together with No.1 fork shaft and shift head and shift forks from the transaxle case.




21. SEPARATE THE NO.1 FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS
a. Mount the shift forks to the vise.
b. Drive out the slotted spring pin from No.1 fork shaft as shown in the figure.




c. Separate the No.1 shift fork, shaft, No.1 shift head, No.1 and No.2 shift fork.




22. REMOVE REVERSE SHIFT FORK AND INTERLOCK PIN




23. REMOVE NO.2 FORK SHAFT
a. Using SST, remove the straight screw plug.
SST 09312-30021




b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Pull out the shaft.
24. REMOVE DIFFERENTIAL ASSEMBLY
25. REMOVE MAGNET




26. MEASURE THIRD AND FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
3rd gear 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
4th gear 0.20 - 0.45 mm (0.0079 - 0.0177 in.)
Maximum clearance:
3rd gear 0.30 mm (0.0118 in.)
4th gear 0.50 mm (0.0197 in.)




27. REMOVE SNAP RING FROM INPUT SHAFT
Using two screwdrivers and a hammer, tap out the snap ring.




28. REMOVE RADIAL BALL BEARING, FOURTH GEAR. NEEDLE ROLLER BEARINGS. SYNCHRONIZER RING AND SPACER FROM INPUT SHAFT
a. Using a press, remove the radial ball bearing and 4th gear.
b. Remove the needle roller bearings, synchronizer ring and spacer.




29. REMOVE SNAP RING
Using snap ring pliers, remove the snap ring.




30. REMOVE NO.2 HUB SLEEVE ASSEMBLY, THIRD GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER BEARINGS
Using a press, remove No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.




31. MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear 0.10 - 0.29 mm (0.0039 - 0.0114 in.)
2nd gear 0.20 - 0.44 mm (0.0079 - 0.0173 in.)
Maximum clearance:
1St gear 0.35 mm (0.0138 in.)
2nd gear 0.50 mm (0.0197 in.)




32. REMOVE RADIAL BALL BEARING, FOURTH DRIVEN GEAR AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
a. Using a press, remove the radial ball bearing and 4th driven gear.
b. Remove the spacer.




33. REMOVE THIRD DRIVEN GEAR, SECOND GEAR, NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING
a. Shift No.1 hub sleeve into the 1st gear.




b. Using a press, remove the 3rd driven gear and 2nd gear.
c. Remove the needle roller bearing, spacer and synchronizer ring.




34. REMOVE SNAP RING
Using two screwdrivers and a hammer, tap out the snap ring.




35. REMOVE NO.1 HUB SLEEVE ASSEMBLY, FIRST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING AND THRUST WASHER
a. Using a press, remove No.1 hub sleeve, 1st gear and synchronizer ring.
b. Remove the needle roller bearing and thrust washer.




36. DISASSEMBLE SHIFT AND SELECT LEVER ASSEMBLY
a. Remove the lever lock pin and nut.
b. Remove the control shift lever.
c. Remove the dust boot.
d. Remove the control shaft cover.




e. Remove the E-ring.




f. Remove the reverse restrict pin holder, spring and No.2 shift inner lever.




g. Using a pin punch and hammer, drive out the slotted spring pin.




h. Remove the shift fork lock plate, No.1 shift inner lever, spring and shift interlock plate.




i. Remove the E-ring from the shaft.