MANUAL TRANSMISSION UNIT REMOVAL


  1. REMOVE FILLER PLUG

    A01DWFVE01

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

  2. REMOVE DRAIN PLUG

    A01DX3FE01

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

  3. REMOVE CLUTCH RELEASE FORK

    A01E2MNE01

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

  4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

    A01DZ9PE01

    1. Remove the clip and release bearing from the release fork.

  5. REMOVE RELEASE FORK SUPPORT

    A01DZHAE01

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

  6. REMOVE CLUTCH RELEASE FORK BOOT

    A01DWHQE01

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

  7. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    A01DZ5HE01

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

      SST
      09817-16011

  8. REMOVE CLUTCH HOUSING

    A01DXQQE01

    1. Remove the 9 bolts.

    2. A01DVVRE01

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

  9. REMOVE RESTRICT PIN

    A01DZC7E01

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

  10. REMOVE CONTROL SHIFT LEVER RETAINER

    A01DYQOE01

    1. Remove the 4 bolts from the extension housing.

    2. Remove the shift lever retainer and oil deflector from the extension housing.

  11. REMOVE SPEEDOMETER DRIVEN GEAR


    1. Remove the bolt and driven gear.

  12. REMOVE SHIFT DETENT BALL

    A01E02JE01

    1. Using a T40 "torx" socket, remove the spring seat from the extension housing.

    2. A01DZEUE01

      Using a magnetic finger, remove the compression spring and shift detent ball from the extension housing.

  13. REMOVE EXTENSION HOUSING

    A01E0HAE01

    1. Remove the bolt from the shift lever housing.

    2. A01DWXOE01

      Remove the 8 bolts.

    3. A01DWEPE01

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

  14. REMOVE TRANSMISSION MAGNET

    A01E0N1E01

    1. Remove the magnet from the extension housing.

  15. REMOVE OIL RECEIVER PIPE

    A01DZMVE01

    1. Remove the receiver pipe from the extension housing.

  16. REMOVE OIL RECEIVER


    1. Remove the bolt and oil receiver.

  17. REMOVE REVERSE RESTRICT PIN

    A01E0M2E01

    1. Using a T40 "torx" socket, remove the plug from the extension housing.

    2. A01DWCWE01

      Using a 5 mm pin punch and hammer, tap out the restrict slotted spring pin from the extension housing.

    3. A01E1BTE01

      Remove the restrict pin from the extension housing.

  18. REMOVE EXTENSION HOUSING OIL SEAL

    A01DVGVE01

    1. Using a screwdriver and hammer, tap out the oil seal from the extension housing.

  19. REMOVE BEARING RETAINER FRONT

    A01E14KE01

    1. Remove the 8 bolts.

    2. w/o Gasket:

      Remove the bearing retainer from the transmission case.

    3. w/ Gasket:

      Remove the bearing retainer and gasket from the transmission case.

  20. REMOVE TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    A01E33UE01

    1. Using a screwdriver, pry out the oil seal from the bearing retainer front.

  21. REMOVE FRONT BEARING SHAFT SNAP RING

    A01DVM9E01

    1. Using a snap ring expander, remove the snap ring from the front bearing.

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

    A01E1K5E01

    1. Using a snap ring expander, remove the snap ring from the front bearing.

  23. REMOVE MANUAL TRANSMISSION CASE

    A01DXE5E01

    1. Stand the transmission as shown in the illustration.

    2. Using a plastic-faced hammer, carefully tap off the transmission case.

    3. Remove the transmission case from the intermediate plate as shown in the illustration.

  24. FIX INTERMEDIATE PLATE

    A01DVEFE01

    1. Fix the intermediate plate in a vise.

  25. REMOVE SHIFT DETENT BALL

    A01DZATE01

    1. Using a T40 "torx" socket, remove the 3 spring seats from the intermediate plate.

    2. A01DYASE01

      Using a magnetic finger, remove the 3 compression springs and 3 shift detent balls from the intermediate plate.

  26. REMOVE NO. 2 SHIFT DETENT BALL

    A01DUY1E01

    1. Using a T40 "torx" socket, remove the spring seat from the intermediate plate.

    2. A01DVP8E01

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

  27. REMOVE NO. 4 SHIFT FORK SHAFT

    A01DV61E01

    1. Remove the bolt from the No. 3 gear shift fork.

    2. A01DYTRE01

      Using 2 screwdrivers and a hammer, tap out the snap ring and 2 reverse shift head rings form the No. 4 shift fork shaft.

    3. A01E22UE01

      Remove the No. 4 shift fork shaft, ball pin shift interlocks and No. 3 gear shift fork from the intermediate plate.

  28. REMOVE NO. 5 SHIFT FORK SHAFT

    A01DWDVE01

    1. Using a 5 mm pin punch and hammer, tap out the slotted spring pin from the reverse shift head.

    2. A01E1XSE01

      Remove the reverse shift head and No. 5 shift fork shaft from the intermediate plate.

  29. REMOVE NO. 3 SHIFT FORK SHAFT

    A01E0O1E01

    1. Using a magnetic finger, remove the No. 2 shift interlock pin with the No. 3 shift fork shaft.

    2. A01DYDUE01

      Remove the shift detent ball and compression spring from the reverse shift fork.

    3. Using a magnetic finger, remove the No. 3 shift interlock pin from the intermediate plate.

  30. REMOVE NO. 3 HEAD GEAR SHIFT

    A01E0EEE01

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

    2. Remove the No. 3 head gear shift from the No. 3 shift fork shaft.

  31. REMOVE NO. 2 SHIFT INTERLOCK PIN

    A01DVGSE01

    1. Using a magnetic finger, remove the No. 2 interlock pin from the No. 1 shift fork shaft.

  32. REMOVE NO. 1 SHIFT FORK SHAFT

    A01DX9SE01

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

    2. A01DYLUE01

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

    3. A01DWLRE01

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

  33. REMOVE NO. 1 SHIFT INTERLOCK PIN

    A01DZO3E01

    1. Using a magnetic finger, remove the No. 1 interlock pin from the intermediate plate.

  34. REMOVE NO. 2 SHIFT FORK SHAFT

    A01DYN5E01

    1. Remove the bolt from the No. 2 gear shift fork.

    2. A01DXVDE01

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

    3. A01E2FRE01

      Remove the No. 2 shift fork shaft, No. 1 gear shift fork and No. 2 gear shift fork from the intermediate plate.

  35. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE

    A01E16HE01

    1. Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.125 to 0.325 mm (0.0049 to 0.0128 in.)
      Maximum clearance
      0.325 mm (0.0128 in.)

  36. REMOVE COUNTER SHAFT 5TH GEAR ASSEMBLY

    A01DWHFE01

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

    2. A01E0QEE01

      Using SST, remove the No. 5 gear spline piece and No. 3 synchronizer ring from the counter gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )
    3. A01DVW5E01

      Remove the 5th gear and 5th gear bearing from the counter gear.

  37. REMOVE 5TH GEAR THRUST WASHER

    A01E15ME01

    1. Remove the thrust washer from the counter gear.

    2. A01DVLAE01

      Using a magnetic finger, remove the thrust washer lock ball from the counter gear.

  38. REMOVE REVERSE SHIFT ARM BRACKET

    A01E09YE01

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

  39. REMOVE REVERSE SHIFT ARM

    A01E1M2E01

    1. Using a screwdriver, pry out the E-ring.

    2. Remove the shift fork from the shift arm.

  40. REMOVE REVERSE IDLER GEAR

    A01DXODE01

    1. Remove the bolt and idler gear shaft stopper from the intermediate plate.

    2. A01E0C7E01

      Remove the idler gear shaft and idler gear from the intermediate plate.

  41. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

    A01DW7KE01

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

      Standard clearance
      0.04 to 0.08 mm (0.0016 to 0.0031 in.)
      Maximum clearance
      0.08 mm (0.0031 in.)

      • If the clearance is greater than the maximum, replace the reverse idler gear.

  42. INSPECT REVERSE IDLER GEAR

    A01E0R2E03

    1. Using a feeler gauge, measure the clearance between the reverse idler gear and reverse shift arm.

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

      • If the clearance is greater than the maximum, replace the reverse idler gear and reverse shift arm.

  43. REMOVE OUTPUT SHAFT REAR BEARING RETAINER

    A01E0ITE01

    1. Using a T40 "torx" socket, remove the 4 screws and rear bearing retainer from the intermediate plate.

  44. REMOVE COUNTER GEAR ASSEMBLY

    A01E2FIE01

    1. Using a snap ring expander, remove the snap ring from the counter shaft center bearing.

    2. A01DXQPE01

      Using SST, remove the center bearing, counter gear and input shaft from the intermediate plate.

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

  45. REMOVE OUTPUT SHAFT ASSEMBLY

    A01E2POE01

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

    2. A01DV4TE01

      Remove the output shaft from the intermediate plate by pulling on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.