MANUAL TRANSMISSION UNIT REMOVAL


  1. REMOVE FILLER PLUG

    A01J5LYE01

    1. Remove the filler plug and gasket from the transmission case.

  2. REMOVE DRAIN PLUG

    A01J468E01

    1. Remove the drain plug and gasket from the transmission case.

  3. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

    A01J4QYE01

    1. Remove the release fork and release bearing from the clutch housing.

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    A01J4HUE01

    1. Remove the clip, and then remove the release bearing from the release fork.

  5. REMOVE RELEASE FORK SUPPORT

    A01J6WGE01

    1. Remove the release fork support from the clutch housing.

  6. REMOVE CLUTCH RELEASE FORK BOOT

    A01J63B

    1. Remove the release fork boot from the clutch housing.

  7. REMOVE CLUTCH HOUSING

    A01J6RI

    1. Remove the 9 bolts.

    2. A01J4CA

      Using a plastic-faced hammer, tap out the clutch housing from the transmission case.

  8. REMOVE SPEEDOMETER DRIVEN GEAR


    1. Remove the bolt and speedometer driven gear.

    2. Remove the O-ring from the speedometer driven gear.

  9. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    A01J54UE01

    1. Using SST, remove the back-up light switch and gasket from the transmission case.

      SST
      09817-16011

  10. REMOVE RESTRICT PIN

    A01J2ZF

    1. Remove the 2 restrict pins from the extension housing.

  11. REMOVE CONTROL SHIFT LEVER RETAINER

    A01J2ZM

    1. Remove the 6 bolts.

    2. Remove the control shift lever retainer.

    3. Remove the control shift lever retainer gasket.

  12. REMOVE EXTENSION HOUSING

    A01J4XME01

    1. Remove the bolt from the shift lever housing.

    2. A01J4SXE01

      Remove the 10 bolts.

    3. A01J5TIE03

      Using a plastic-faced hammer, tap the extension housing and remove the shift lever housing and shift and select lever from the transmission case.

  13. REMOVE OIL RECEIVER PIPE

    A01J5V5E01

  14. REMOVE OIL RECEIVER


    1. Remove the bolt and oil receiver.

  15. REMOVE REVERSE RESTRICT PIN

    A01J6JGE01

    1. Using a T40 ''TORX'' socket wrench, remove the plug.

    2. A01J7EKE01

      Using a 5 mm pin punch and a hammer, tap out the restrict slotted pin.

    3. A01J38UE01

      Remove the restrict pin.

  16. REMOVE EXTENSION HOUSING OIL SEAL


    1. Using a screwdriver and a hammer, tap out the oil seal from the transfer adapter.

  17. REMOVE FRONT BEARING RETAINER

    A01J6TGE01

    1. Remove the 8 bolts.

    2. A01J3CWE01

      Using a brass bar and a hammer, tap out the retainer from the transmission case.

  18. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    A01J756E01

    1. Fix the front bearing retainer in a vise.

    2. Using SST, tap out the oil seal.

      SST
      09308-00010

  19. REMOVE FRONT BEARING SHAFT SNAP RING

    A01J6PME01

    1. Using a snap ring expander, remove the snap ring from the transmission case.

  20. REMOVE NO. 1 COUNTER GEAR FRONT BEARING SNAP RING

    A01J5NRE01

    1. Using a snap ring expander, remove the snap ring from the transmission case.

  21. REMOVE MANUAL TRANSMISSION CASE

    A01J3FHE01

    1. Using a brass bar and a hammer, tap out the transmission case from the intermediate plate.

  22. REMOVE TRANSMISSION MAGNET

    A01J5QTE01

    1. Remove the magnet from the intermediate plate.

  23. FIX INTERMEDIATE PLATE

    A01J4SOE01

    1. Fix the intermediate plate in a vise between the aluminum plates.

  24. REMOVE NO. 1 SHIFT DETENT BALL SPRING SEAT

    A01J6WWE01

    1. Using a T40 ''TORX'' socket wrench, remove the spring seat from the intermediate plate.

    2. A01J6YME01

      Using a magnetic hand, remove the compression spring and detent ball from the intermediate plate.

    3. A01J63OE01

      Using a T40 ''TORX'' socket wrench, remove the 2 spring seats from the intermediate plate.

    4. A01J6GTE01

      Using a magnetic hand, remove the 2 compression springs and 2 detent balls from the intermediate plate.

  25. REMOVE NO. 2 SHIFT FORK SHAFT

    A01J4BVE01

    1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 shift fork shaft.

      Note

      Use a cloth to prevent the snap ring from flying off.

    2. A01J65RE01

      Remove the bolt from the No. 2 shift fork.

    3. A01J70VE01

      Remove the No. 2 shift fork shaft from the intermediate plate.

    4. A01J2YKE01

      Remove the No. 2 shift fork from the No. 2 transmission hub sleeve.

    5. A01J4QBE01

      Using a magnetic hand, remove the No. 1 shift interlock roller and shift interlock pin from the intermediate plate.

  26. REMOVE NO. 1 SHIFT FORK SHAFT

    A01J5G3E01

    1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 1 shift fork shaft.

      Note

      Use a cloth to prevent the snap ring from flying off.

    2. A01J5M3E01

      Remove the shift fork set bolt from the No. 1 shift fork.

    3. A01J5ZYE01

      Remove the No. 1 shift fork shaft from the intermediate plate.

    4. A01J4RYE01

      Remove the No. 1 shift fork from the reverse gear.

    5. A01J33JE01

      Using a magnetic hand, remove the No. 1 shift interlock roller from the intermediate plate.

  27. REMOVE NO. 3 SHIFT FORK SHAFT

    A01J42U

    1. Using a 5 mm pin punch and a hammer, tap out the shift fork set slotted spring pin from the No. 3 shift fork.

    2. A01J4N6E01

      Using 2 screwdrivers and a hammer, tap out the snap ring from the shift fork shaft.

      Note

      Use a cloth to prevent the snap ring from flying off.

    3. A01J6ZY

      Remove the No. 3 shift fork and No. 3 shift fork shaft from the intermediate plate.

    4. A01J33JE02

      Using a magnetic hand, remove the No. 1 shift interlock roller from the intermediate plate.

    5. A01J406E01

      Using a magnetic hand, remove the reverse shift fork ball from the reverse shift fork.

  28. REMOVE NO. 4 SHIFT FORK SHAFT

    A01J59DE01

    1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 4 shift fork shaft.

      Note

      Use a cloth to prevent the snap ring from flying off.

    2. A01J5XWE01

      Remove the No. 4 shift fork shaft from the intermediate plate.

      Note

      Cover the hole with a cloth to prevent the reverse shift fork ball from popping out.

    3. A01J4DUE01

      Using a magnetic hand, remove the reverse shift fork ball and reverse shift fork return compression spring from the reverse shift fork.

  29. REMOVE REVERSE SHIFT FORK

    A01J57EE01

    1. Remove the reverse shift fork (with the reverse shift arm) from the intermediate plate.

    2. A01J74YE01

      Using a screwdriver, pry out the E-ring and reverse shift fork from the reverse shift arm.

  30. REMOVE REVERSE SHIFT ARM BRACKET

    A01J76NE02

    1. Remove the 2 bolts and reverse shift arm bracket from the intermediate plate.

  31. REMOVE SPEEDOMETER DRIVE GEAR

    A01J440E03

    1. Using snap ring pliers, remove the snap ring.

    2. Remove the drive gear.

    3. Using a magnetic hand, remove the ball.

    4. Using snap ring pliers, remove the snap ring.

  32. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    A01J564

    1. Using 2 screwdrivers and a hammer, tap out the shaft snap ring from the output shaft.

      Note

      Use a cloth to prevent the snap ring from flying off.

  33. REMOVE OUTPUT SHAFT REAR BEARING

    A01J459E01

    1. Using SST, remove the rear bearing and output shaft spacer from the output shaft.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

  34. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE


    1. A01J7LFE01

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)

      If the clearance is not as specified, replace the counter 5th gear.

  35. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE

    A01J43PE01

    1. Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.0006 to 0.0027 in.)

      If the clearance is not as specified, replace the counter 5th gear bearing with a new one.

  36. REMOVE COUNTER GEAR REAR SHAFT SNAP RING

    A01J5UI

    1. Using 2 screwdrivers and a hammer, tap out the snap ring from the counter gear.

      Note

      Use a cloth to prevent the snap ring from flying off.

  37. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. A01J56O

      Remove the No. 3 transmission hub sleeve from the counter 5th gear.

  38. REMOVE COUNTER 5TH GEAR


    1. A01J6U9E01

      Using SST, remove the counter 5th gear together with the 2 No. 3 synchromesh shifting keys, 2 No. 3 synchromesh shifting key springs, No. 3 synchronizer ring and No. 5 gear spring piece from the counter gear.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )

  39. REMOVE NO. 5 GEAR SPRING PIECE


    1. A01J6CX

      Remove the No. 5 gear spring piece from the counter 5th gear.

  40. REMOVE NO. 3 SYNCHRONIZER RING


    1. Remove the synchronizer ring from the counter 5th gear.

  41. REMOVE COUNTER 5TH GEAR BEARING


    1. A01J591E01

      Remove the bearing from the counter 5th gear.

  42. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING


    1. A01J4KP

      Using a snap ring expander, remove the snap ring.

    2. A01J4GI

      Remove the No. 3 synchromesh shifting key spring and 2 No. 3 synchromesh shifting keys from the counter 5th gear.

  43. REMOVE 5TH GEAR THRUST WASHER

    A01J4Y7

    1. Remove the thrust washer from the counter gear.

  44. REMOVE 5TH GEAR THRUST WASHER PIN

    A01J64F

    1. Remove the thrust washer pin from the counter gear.

  45. REMOVE REAR BEARING RETAINER

    A01J3UDE01

    1. Remove the 4 bolts and bearing retainer from the intermediate plate.

  46. REMOVE REVERSE IDLER GEAR

    A01J7ONE01

    1. Pull out the reverse idler gear shaft to the rear side and remove the reverse idler gear from the intermediate plate.

  47. REMOVE COUNTER SHAFT CENTER BEARING

    A01J7MOE01

    1. Using a snap ring expander, remove the snap ring.

    2. A01J38I

      Using SST, remove the center bearing from the intermediate plate.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011 )

      Tech Tips

      Remove the bearing while tapping the tip of the counter gear so that the counter gear does not hit the side wall of the output shaft gear by being pushed forward.

  48. REMOVE COUNTER GEAR

    A01J77UE01

    1. Remove the counter gear from the intermediate plate.

  49. REMOVE INPUT SHAFT ASSEMBLY

    A01J4G7E01

    1. Remove the input shaft and No. 2 synchronizer ring from the output shaft.

      Note

      Do not drop the input shaft bearing and the No. 2 synchronizer ring.

  50. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    A01J4OD

    1. Using a snap ring expander, remove the snap ring from the output shaft.

  51. REMOVE OUTPUT SHAFT ASSEMBLY

    A01J7CD

    1. Using a plastic-faced hammer, remove the output shaft by tapping the intermediate plate.

  52. INSPECT NO. 3 SYNCHRONIZER RING

    A01J6THE01

    1. Apply gear oil to the cone part of the No. 5 gear spline piece, and check that it does not turn in both directions while pushing the No. 3 synchronizer ring to the No. 5 gear spline piece.

      If it can turn, replace the No. 3 synchronizer ring.

    2. A01J3MXE01

      Push the No. 3 synchronizer ring outer to the cone part of the No. 5 gear spline piece. Measure the clearance between the No. 3 synchronizer ring outer and No. 5 gear spline piece.

      Standard clearance
      0.68 to 1.32 mm (0.0268 to 0.0519 in.)

      If the clearance is not as specified, replace No. 3 synchronizer ring outer with a new one.

  53. INSPECT NO. 3 TRANSMISSION HUB SLEEVE

    A01J6GOE01

    1. Check the sliding condition between the counter shaft 5th gear and No. 3 transmission hub sleeve.

    2. Check the tip of the spline gear of the No. 3 transmission hub sleeve for wear.

      If there are any defects, replace the No. 3 transmission hub sleeve.

    3. A01J5QQE02

      Using a vernier caliper, measure the No. 3 transmission hub sleeve groove and the thickness of the claw part of the No. 3 shift fork to calculate the clearance.

      Standard clearance
      0.26 to 0.84 mm (0.0102 to 0.0331 in.)

      If the clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 3 shift fork with new ones.

  54. INSPECT COUNTER 5TH GEAR

    A01J4ECE01

    1. Using a cylinder gauge, measure the inside diameter of the counter 5th gear.

      Standard inside diameter
      38.015 to 38.040 mm (1.4967 to 1.4976 in.)
      Maximum inside diameter
      38.040 mm (1.4976 in.)

      If the inside diameter is greater than the maximum, replace the counter shaft 5th gear with a new one.

  55. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

    A01J3MNE03

    1. Using a caliper gauge, measure the inside diameter of the reverse idler gear.

      Standard inside diameter
      24.040 to 24.061 mm (0.9465 to 0.9473 in.)
      Maximum inside diameter
      24.061 mm (0.9473 in.)

      If the inside diameter is greater than the maximum, replace the reverse idler gear with a new one.

    2. Using a micrometer, measure the diameter of the sliding part of the reverse idler gear on the reverse idler gear shaft.

      Standard diameter
      23.979 to 24.000 mm (0.9441 to 0.9449 in.)
      Minimum diameter
      23.979 mm (0.9441 in.)

      If the diameter is less than the minimum, replace the reverse idler gear shaft.

    3. A01J76UE01

      Using a feeler gauge, measure the thrust clearance of the shoe part between the reverse idler gear and reverse shift arm.

      Standard clearance
      0.05 to 0.35 mm (0.0020 to 0.0138 in.)

      If the clearance is not as specified, replace the reverse idler gear and reverse shift arm.

  56. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

    A01J7OOE01

    1. Install the reverse idler gear on the reverse idler gear shaft, and clamp it to a vise.

    2. Using a dial indicator, measure the radical clearance.

      Standard clearance
      0.040 to 0.082 mm (0.0016 to 0.0032 in.)

      If the clearance is not as specified, replace the reverse idler gear.