Page 865 of 2893
13-96Manual Transmission
Transmission Installation (cont’d)
12x1.25mm
64 N·m (6.5 kgf·m, 47 lbf·ft)
A6x1.0mm
12 N·m
(1.2 kgf·m, 9 lbf·ft)
6x1.0mm
12 N·m
(1.2 kgf·m,
9lbf·ft)
A B
C A
33. Install the two upper transmission mounting bolts.
34. Install the engine harness cover (A). 35. Install the air cleaner housing mounting bracket.
36. Install the harness clips (A) on the shift cable
bracket (B) and the harness bracket (C).
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Page 866 of 2893
ÎÎ
’06 model
’07-09 models
13-97
8x1.25mm
27 N·m (2.8 kgf·m, 20 lbf·ft)
C B
C
A
(P/N 08C30-B0234M) E
D
C
B
C
A
(P/N 08C30-B0234M) 8x1.25mm
27 N·m (2.8 kgf·m, 20 lbf·ft)
A
D
B C
37. Apply a light coat of silicone grease (P/N 08C30-
B0234M) to the shift cable ends (A).
NOTE: Make sure not to get any silicone grease on
the terminal part of the connectors and switches,
especially if you have silicone grease on your
hands or gloves
38. Install the shift cable bracket (B) and the shift cables(C), then install new cotter pins (D) or lock pins (E).
39. Connect the back-up light switch connector (A), the output shaft (countershaft) speed sensor connector
(B), and the reverse lockout solenoid connector (C).
Install the harness clips (D).
(cont’d)
Replace.
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Page 867 of 2893

13-98Manual Transmission
Transmission Installation (cont’d)
6x1.0mm
9.8 N·m
(1.0 kgf·m,
7.2 lbf·ft)
8x1.25mm
22 N·m (2.2 kgf·m, 16 lbf·ft)
(P/N 08798-9002) B
A
6x1.0mm
9.8 N·m
(1.0 kgf·m, 7.2 lbf·ft) 6x1.0mm
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
6x1.0mm
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft) B
A
C
C
D
40. Apply super high temp urea grease (P/N 08798-
9002) to the end of the slave cylinder pushrod.
Install the slave cylinder (A), then install the clutch
line bracket (B). Be careful not to bend the clutch
line.
41. Install the battery base (A) with the coolant reservoir (B). 42. Install the harness clips (C) and the intake air duct
(D).
43. Install the air cleaner assembly (see page 11-345).
44. Do the battery installation procedure (see page 22-69).
45. Install the under-cowl panel and the cowl cover (see page 20-163).
46. Check the shift lever and the clutch operation.
47. Check the wheel alignment (see page 18-5).
48. Test-drive the vehicle.
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Page 868 of 2893
Î
(#'
!)
Exploded View - Clutch Housing
13-99
Transmission Disassembly
MAINSHAFT ASSEMBLY COUNTERSHAFT ASSEMBLY REVERSE IDLER GEAR BALL BEARING
REVERSE IDLER GEAR SHAFT
14x20mmDOWELPIN
MAGNET DIFFERENTIAL ASSEMBLY
OIL GUIDE PLATE C BEARING SET PLATE
NEEDLE BEARING
28 mm WASHER 28 mm SPRING WASHER
6 mm SPECIAL BOLT
REVERSE SHIFT FORK
SHIFT FORK ASSEMBLY
15 N·m (1.5 kgf·m, 11 lbf·ft)72 mm SNAP RING
6 mm FLANGE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft)
35x58x8mmOILSEAL 28x43x7mmOILSEAL 20 mm WASHER BACK-UP LIGHT SWITCH
29N·m(3.0kgf·m,22lbf·ft)
20 mm BOLT
44N·m(4.5kgf·m,33lbf·ft) CLUTCH HOUSING
(cont’d)
Replace. Replace.Replace.
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Page 869 of 2893

Î
Exploded View - Transmission Housing
13-100Manual Transmission
Transmission Disassembly (cont’d)
TRANSMISSION HOUSING
32 mm SEALING CAP
34 N·m (3.5 kgf·m, 25 lbf·ft)
10 mm SEALING WASHER
FILLER PLUG
44 N·m (4.5 kgf·m, 33 lbf·ft)
40x56x8mmOILSEAL
10 mm FLANGE BOLT
44 N·m (4.5 kgf·m, 33 lbf·ft)
14 mm SEALING WASHER
TRANSMISSION HANGER A 8 mm FLANGE BOLT
27 N·m (2.8 kgf·m, 20 lbf·ft)
INTERLOCK BOLT
39 N·m (4.0 kgf·m, 29 lbf·ft)
OIL GUIDE PLATE M
72 mm SHIM
OIL GUTTER PLATE
DRAIN PLUG
39 N·m (4.0 kgf·m, 29 lbf·ft) 20 mm SEALING WASHER STEEL BALL SPRING
TRANSMISSION HANGER B DETENT BOLT
22 N·m (2.2 kgf·m, 16 lbf·ft)
12 mm SEALING WASHER
HARNESS BRACKET A
6 x 30 mm FLANGE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft) 8x14mmDOWELPIN
CHANGE LEVER ASSEMBLY TRANSMISSION HANGER
10 mm FLANGE BOLT
44 N·m (4.5 kgf·m, 33 lbf·ft)
6 x 20 mm FLANGE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft) 6 mm FLANGE BOLT
12 N·m (1.2 kgf·m, 9 lbf·ft) OUTPUT SHAFT (COUNTERSHAFT)
SPEED SENSOR
O-RING
80 mm SHIM Replace.
Replace.
Replace. Replace. Replace.Replace.
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Page 870 of 2893
Î
Î
13-101
C
A
A
D E
B C
F
D
B
AB A
D
D
C B
AB
D
C D
D
E
F
NOTE: Place the clutch housing on two pieces of wood
thick enough to keep the mainshaft from hitting the
workbench.
1. Remove the release fork and the release bearing (see page 12-24).
2. Remove the detent bolts (A), the 12 mm sealing washers (B) the springs (C), the steel balls (D), and
the back-up light switch (E). Then remove the
transmission hanger (F).
3. Remove the 20 mm bolt (A) and the 20 mm sealing washer (B). 4. Remove the interlock bolt (B), the change lever
assembly(C),the8x14mmdowelpins(D),and
harness bracket A.
5. Remove the drain plug (A), the filler plug (B), the 10 mm flange bolt (C), and the sealing washers (D).
6. Remove the output shaft (countershaft) speed sensor (E) with the O-ring (F).
(cont’d)
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Page 871 of 2893
Î
Î
13-102 Manual Transmission
Transmission Disassembly (cont’d)
A
B
A
D B
C
D
D A
B
A
7. Loosen the 8 mm flange bolts in a crisscross pattern in several steps, then remove them with
transmission hanger A and transmission hanger B.
8. Remove the 32 mm sealing cap (A).
9. While expanding the 72 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift
the transmission housing (C). Release the snap ring
pliers, and remove the transmission housing and
the three 14 x 20 mm dowel pins (D). 10. Remove the reverse idler gear (A) and the reverse
idler gear shaft (B).
11. Remove the reverse shift fork (A).
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Page 872 of 2893
Î
ÎÎ
13-103
D
E B
C
F A
A B M
B
A
12. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and
the countershaft assembly (B) with the shift fork
assembly (C) from the clutch housing (D).
13. Remove the 28 mm spring washer (E) and the 28 mm washer (F).
14. Remove the differential assembly (A) and the magnet (B). 15. Remove the oil gutter plate (A), the 72 mm shim (B),
and oil guide plate M.
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