1. Install the input shaft oil seal with the special tool (09431-21000).
2. Install the front oil seal with the special tool (09431-21000).
3. Install the output shaft oil guide.
4. With a special tool (09532-11500) Install the output shaft bearing outer race.
5. Install the control shaft assembly.
6. Install differential assembly.
7. Install the drive shaft and output shaft assembly at the same time.
8. Install the bearing holder.
9. Reinstall the shift rod assemblies.
- 1) Set the 1st and 2nd gear synchronizer cage to neutral.
- 2) Set the 3rd and 4th gear synchronizer cage to neutral.
- 3) Install shift rod assemblies and fork.
10. Installing the spring pin.
- 1) Install the spring pins with the special tool (09414-11100) or beard with a thin cylindrical end.
- 2) When installing, ensure that the slot of the new spring pin aligns with the center line of the stem.
11. Install the rear code gear.
12. Install the reverse lever.
13. Using a special tool (09431-21200) Install a new input shaft oil seal in the transmission case.
Warning. The oil seal cannot be reused.
14. Install the output shaft bearing outer race and spacer using tools (09500-11000, 09432-22100A).
15. Installation of the spacer ring.
- 1) Install two pieces of solder with a diameter of 3 mm on the outer ring of the bearing, as shown in the figure.
- 2) Temporarily install the gearbox housing and tighten the bolts to the required torque, then remove the housing.
- 3) Remove flattened pieces of solder.
- 4) Measure the thickness of the flattened solder. Select and install appropriate spacer rings to provide standard axial clearances (mm):
- Front bearing of the input shaft - 0.01-0.12
- Rear bearing of the drive shaft - 0.01-0.09
- Rear output shaft bearing - 0.01-0.15
- Rear differential bearing - 0.05-0.17
- The gap between the gear teeth in the differential - 0.025-0.15
16. Install the oil guide in the crankcase, gearbox.
17. Apply sealant MS721-40 to the mating surface of the gearbox housing adjacent to the clutch housing.
18. Install the crankcase, gearboxes on the clutch housing and tighten the bolts.
19. Use a screwdriver to center the shaft.
20. Tighten the reverse gear axle bolt to the specified torque (43-55 Nm).
21. Install balls, springs and sealed bolts.
22. Using a special tool (094434-33300) Install the output shaft gear.
23. Install the rear bearing and spacer onto the drive shaft, then install the circlip. Install the 5th gear bushing.
24. Install the 5th gear, needle roller bearing, synchronizer ring and hub.
25. Install the 5th shift fork and synchronizer clutch at the same time.
26. Installing the locknut.
- 1) Engage first gear with the shift lever and select lever.
- 2) Engage the clutch with the 5th gear.
- 3) Tighten the locknut to the required torque.
27. Using a special tool (09414-11100) or barb with a thin barrel end, install a new spring pin, making sure that the notch lines up with the center line of the shift rod.
28. Apply sealant MS721-40 to the rear cover joint and install the cover.
29. Install the speedometer driven gear assembly.
30. Establish the switch of a lantern of a backing.
31. Install the mounting bracket.
32. Install selector lever assembly.