Transmission Unit

TRANSMISSION UNIT





1. Remove 12 fastening bolts and separate rear case (3).
2. Remove clutch release bearing (2).
3. Remove 8 clutch housing bolts and then remove clutch housing (1).





4. Remove 8 bolts and pull out input shaft bearing retainer (1) by using large size screwdrivers (2) and clean cloth (3).

CAUTION: When pulling out, do not scratch the transmission case surface contacting with the clutch housing.





5. Remove 10 bolts and separate cases (1,2) by using special tool.
Special tool (A): 09912-34510





6. If equipped with scissors gears (3,5), put match mark (1) (paint) on teeth of low (4) and reverse (6) gear assembly as shown in the figure before taking out input and main shaft assembly from lowercase (2).
7. Take out input and main shaft assembly.





8. Remove bearing circlip (2) at the rear part of counter shaft by using screwdriver (1).





9. Remove bolt (3) for reverse idle gear shaft (2) and then remove idle gear (1) and shaft (2) as a set.





10. Remove center bearing plate (1) by removing its 2 bolts (2).





11. Remove outside circlip (1) of front bearing (2) on counter shaft.





12. Using plastic hammer, drive counter shaft (1) rearward.





13. Pull out 5th gear (2) and rear bearing (1) with bearing puller (3) and press.

NOTE: Apply pressing force while adjusting position of front bearing so that it will fit in its original position (hole in lower case). Be sure to set flat face of puller (3) against 5th gear so as not to cause damage to teeth.

14. In the same manner as (2), drive counter shaft rearward again.





15. Pull out reverse gear (1) with bearing puller (2) and press.
16. Pull out roller bearing by hand and then remove shaft from lower case.





17. Remove circlip (3) of counter shaft (1) front bearing (2) and pull out bearing (2) by using puller.
Special tool (B): 09913-60910





18. Remove circlip (2), friction gear retainer (3), friction gear spring (4), friction gear (5) and pin (6) from counter shaft (1) in that order.