Page 25 of 34
Front Case
SHIFT SHAFT OIL SEAL
Removal
+Use a screwdriver to pry out old seal.
+Be careful not to damage case.
+Always replace with a new one whenever it has been removed.
Installation
+Install new shift shaft oil seal until ¯ush with case.
+Before installing, apply multi-purpose grease to seal lip.
Front Case Cover
Removal
+Take out old seal from inside of front case cover.
+Be careful not to damage front case cover.
Installation
+Install new front case cover oil seal until it stops.
+Before installing, apply multi-purpose grease to seal lip.
Center Case
CENTER CASE OIL SEAL
Removal
+Remove center case oil seal.
SMT138B
SMT139B
SMT263D
SMT141B
SMT146B
REPAIR FOR COMPONENT PARTS
TF-24
Page 26 of 34
Installation
+Install center case oil seal.
Bearing Retainer
OIL CATCHER
Removal
+Drive out oil catcher from inside of bearing retainer.
+Be careful not to damage bearing retainer.
Installation
+Install oil catcher until it stops.
+Be careful not to damage or distort oil catcher or bearing
retainer.
+Before installing, apply multi-purpose grease to seal lip.
Rear Case
REAR OIL SEAL
Removal
+Pull out rear oil seal.
Installation
+Install new rear oil seal until it stops.
+Before installing, apply multi-purpose grease to seal lip.
SMT147B
SMT142B
SMT143B
SMT144B
SMT145B
REPAIR FOR COMPONENT PARTS
TF-25
Page 28 of 34
1. Install cross shaft.
2. Assemble front case.
a. Install main gear assembly by tapping it lightly with a soft ham-
mer.
b. Apply sealant to the mating surface and bolts of front case
cover and install it on front case.
+Apply recommended sealant to these ten bolts.
+Tightening torque
A:
:16-21Nzm (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
B:
:19-24Nzm (1.9 - 2.4 kg-m, 14 - 17 ft-lb)
c. Apply gear oil to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping it lightly with a soft
hammer.
SMT151B
SMT152B
SMT153B
SMT326A
SMT264D
ASSEMBLY
TF-27
Page 30 of 34
b. Select suitable shim using SDS table as a guide.
Counter gear rear bearing shim:
Refer to SDS, TF-33.
4. Place suitable shim on counter gear rear bearing with grease.
5. Apply gear oil to each part in front case.
6. Install mainshaft on center case.
a. Install mainshaft on center case by tapping it lightly.
+Apply gear oil to mainshaft front bearing.
b. Install bearing retainer.
c. Install low gear and its bearing to mainshaft.
+Apply gear oil to needle bearing.
SMT157B
SMT158B
SMT159B
SMT407A
SMT160B
ASSEMBLY
TF-29
Page 32 of 34
c. Apply gear oil to needle bearings and install them into front
drive sprocket.
+These needle bearings can be easily installed if front drive
sprocket is rotated during their installation.
d. Install 2-4 coupling sleeve with 2-4 shift fork.
+Pay attention to direction of coupling sleeve.
e. Install shifting inserts and spread spring.
+Pay attention to direction of shifting inserts.
f. Install baulk ring and then install clutch gear.
g. Install mainshaft rear bearing.
+Pay attention to its direction.
SMT166B
SMT167B
SMT168B
SMT169B
SMT170B
ASSEMBLY
TF-31
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h. Install snap ring to 2-4 shift rod.
i. Install speedometer drive gear and oil gutter.
j. Apply gear oil to each part in center case.
9. Apply sealant to mating surface. Set center case assembly onto
front case, then tighten bolts.
10. Install front and rear companion ¯anges and center brake com-
ponents.
SMT107B
SMT106B
SMT171B
ASSEMBLY
TF-32