Transmission

Order

Job/Part

Q'ty

Remarks

12

Main axle assembly

1

13

Oil pipe

1

14

Oil baffle plate

1

15

Thrust plate

1

16

Washer

1

For installation, reverse the removal

procedure.

Order

Job/Part

Q'ty

Remarks

Disassembling the main axle

Disassemble the parts in the order listed.

assembly

©

Bearing

1

(2)

2nd pinion gear

1

(3

Toothed lock washer

1

®

Toothed lock washer retainer

1

©

6th pinion gear

1

®

Collar

1

®

Washer

1

®

Circlip

1

®

3rd pinion gear

1

®

Circlip

1

®

Washer

1

©

5th pinion gear

1

Collar

1

<9

Main axle

1

Order

Job/Part

Q'ty

Remarks

© ©

Bearing housing Bearing

1 1

For installation, reverse the removal procedure.

Order

Job/Part

Q'ty

Remarks

Disassembling the drive axle

Disassemble the parts in the order listed.

assembly

©

Washer

1

®

1st wheel gear

1

®

Collar

1

®

5th wheel gear

1

®

Circlip

1

®

Washer

1

®

Collar

1

®

3rd wheel gear

1

®

Toothed lock washer

1

Toothed lock washer retainer

1

©

4th wheel gear

1

Collar

1

13

Washer

1

14

Circlip

1

Order

Job/Part

Q'ty

Remarks

®

6th wheel gear

1

16

Circlip

1

®

Washer

1

2nd wheel gear

1

19

Collar

1

20

Collar

1

21

Oil seal

1

Bearing

1

23

Circlip

1

24

Drive axle

1

For installation, reverse the removal

procedure.

REMOVING THE TRANSMISSION

1. Remove: • main axle assembly ® (with the Torx® wrench T30)

EAS00420

a. Insert two bolts (2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing.

b. Tighten the bolts until they contact the crank-case surface.

c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase.

EAS00421

CHECKING THE SHIFT FORKS

The following procedure applies to all of the shift forks.

• shift fork pawl (2) Bends/damage/scoring/wear ^ Replace the shift fork.

2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends ^ Replace.

A WARNING

Do not attempt to straighten a bent shift fork guide bar.

3. Check: • shift fork movement (along the shift fork guide bar) Rough movement ^ Replace the shift forks and shift fork guide bar as a set.

CHECKING THE SHIFT DRUM ASSEMBLY

• shift drum grooves Damage/scratches/wear ^ Replace the shift drum assembly.

• shift drum segment ® Damage/wear ^ Replace the shift drum assembly.

• shift drum bearing (2) Damage/pitting ^ Replace the shift drum assembly.

CHECKING THE TRANSMISSION

1. Measure: • main axle runout (with a centering device and dial gauge ®) Out of specification ^ Replace the main axle.

Main axle runout limit 0.02 mm (0.0008 in)

Main axle runout limit 0.02 mm (0.0008 in)

2. Measure: • drive axle runout (with a centering device and dial gauge ®) Out of specification ^ Replace the drive axle.

Drive axle runout limit 0.02 mm (0.0008 in)

Drive axle runout limit 0.02 mm (0.0008 in)

• transmission gears

Blue discoloration/pitting/wear ^ Replace the defective gear(s).

• transmission gear dogs Cracks/damage/rounded edges ^ Replace the defective gear(s).

EAS00422

EAS00425

• transmission gear engagement

(each pinion gear to its respective wheel gear)

Incorrect ^ Reassemble the transmission axle assemblies.

• transmission gear movement

Rough movement ^ Replace the defective part(s).

Bends/damage/looseness ^ Replace.

EAS00430

INSTALLING THE TRANSMISSION

1. Install:

• main axle assembly (2) (with the Torx® wrench T30)

Make sure to caulk the bolts at three positions after installing the bearing housing.

2. Install:

• shift fork guide bar

• The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: "R", "C", "L".

• Carefully position the shift forks so that they are installed correctly into the transmission gears.

• Install shift fork "C" into the groove in the 3rd and 4th pinion gear on the main axle.

3. Install:

• shift fork "R" ® and "L" (

• shift fork guide bar

• shift drum retainer

NOTE:

• Install shift fork "L" into the groove in the 6th wheel gear and shift fork "R" into the groove in the 5th wheel gear on the drive axle.

• Make sure that the drive axle bearing circlip ® is inserted into the grooves in the upper crank-case.

9. Check: • transmission Rough movement ^ Repair.

NOTE:

Oil each gear, shaft, and bearing thoroughly.

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