Disassembly

Transmission Disassembly





Exploded View - Clutch Housing





Exploded View - Transmission Housing

NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.





1. Remove the detent bolts (A), springs, steel balls and back-up light switch (B).
2. Remove the transmission hanger (C), 20 mm bolt (D), and 20 mm washer (E).





3. Remove the interlock bolt (B), change lever assembly (C), 8 x 14 mm dowel pins (D), and harness bracket A.





4. Remove the filler plug (A), 10 mm flange bolt (B), mount bracket collar (C).
5. Remove the countershaft speed sensor (D), plain washer (E), and O-ring (F).
6. Remove the 8 mm special bolts (left-hand threads and black color) in a crisscross pattern in several steps.





7. Remove transmission hanger A, transmission hanger B, harness bracket B (C), and mount bracket collar (D).





8. Remove the 32 mm sealing cap (A).
9. Expand the 72 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove with snap ring pliers.
10. Remove the transmission housing (C) and 14 x 20 mm dowel pins (D).





11. Remove the reverse idler gear (A), reverse gear shaft (B), and 20 x 36 x 2 mm thrust washer (C).





12. Remove the reverse shift fork.





13. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift forks (C) from the clutch housing (D).
14. Remove the 28 mm spring washer (E) and 28 mm washer (F).





15. Remove the differential assembly (A) and magnet (B).





16. Remove the oil gutter plate (A), 72 mm shim (B), and oil guide plate M.





17. Remove the drain plug (A), drain plug washer (B), and release bearing guide (C).