Page 1241 of 2893

Î
(#'
")
14-319
Secondary Shaft Disassembly, Inspection, and Reassembly
CONICAL
SPRING
WASHER
THRUST NEEDLE
BEARING
1ST GEAR TRANSMISSION
HOUSING BEARING
1ST/3RD CLUTCH O-RINGS THRUST WASHER,
40 x 51.5 mm
THRUST NEEDLE BEARING
2ND GEAR
NEEDLE BEARINGTHRUST NEEDLE BEARING IDLER GEAR
THRUST NEEDLE BEARING
SEALING RINGS,
29 mm
SET RING 3RD GEAR
SECONDARY SHAFT
THRUST NEEDLE
BEARING
NEEDLE BEARING
THRUST NEEDLE
BEARING
THRUST WASHER,
37x58mm
O-RINGS
2ND CLUTCH NEEDLE BEARING
3RD GEAR COLLAR
LOCKNUT (FLANGE NUT)
24x1.25mm
Left-hand threads
1. Inspect the thrust needle bearing and the needle bearing for galling and r
ough movement.
2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surface for scoring and excessive wear.
4. Before installing new O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer and the idler gear in the direction shown.
7. Replace the locknut and the conical spring washer with new ones when assembling the transmission. The locknut has left-hand threads.
8. Check the clearance of 2nd gear (see page 14-321) and 1st gear (see page 14-322).
Replace.
Replace. Selective part
Replace.
Replace. Selective part
Replace. Replace.
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Page 1242 of 2893
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Special Tools Required
Removal
Installation
14-320Shafts and Clutches
Secondary Shaft Ball Bearing, Idler Gear Removal and Installation
C
A B
E D
B
C
A
07QAD-P0A0100
Attachment, 42 mm I.D. 07QAD-P0A0100
Place a spacer (A) on the secondary shaft (B), and set
the puller (C) under the idler gear (D), then remove the
idler gear and the ball bearing (E).
Install the idler gear (A) on the secondary shaft (B), and
install the ball bearing (C) over the idler gear using the
42 mm I.D. attachment and a press.
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Page 1243 of 2893
Î
(#'
") µµ
Standard: 0.04 0.12 mm (0.002 0.005 in.)
14-321
Secondary Shaft 2nd Gear Axial Clearance Inspection
G
AB
C
D
E
F H C
A B
C 37x58mm
THRUST WASHER
1. Install the thrust needle bearing (A), the needle
bearing (B), 2nd gear (C), the thrust needle bearing
(D), the 37 x 58 mm thrust washer (E), and the 2nd
clutch (F) on the secondary shaft (G), then secure
them with the set ring (H). 2. Measure the clearance between the snap ring (A)
and the 2nd clutch guide (B) using a feeler gauge
(C), in at least three places. Use the average as the
actual clearance.
(cont’d)
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Page 1244 of 2893

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THRUST WASHER, 37 x 58 mm
No. Part Number Thickness Special Tools Required
14-32214-322Shafts and Clutches
Secondary Shaft 2nd Gear Axial
Clearance Inspection (cont’d)
Secondary Shaft 1st Gear Axial
Clearance Inspection
L
24x1.25mm
29N·m(3.0kgf·m,22lbf·ft)
K
J I
G
F
E
D
C
B A
H
3. If the clearance is out of standard, remove the 37 x 58 mm thrust washer and measure its
thickness.
4. Select and install a new thrust washer, then recheck.
1 90511-PRP-010 3.900 mm (0.154 in.)
2 90512-PRP-010 3.925 mm (0.155 in.)
3 90513-PRP-010 3.950 mm (0.156 in.)
4 90514-PRP-010 3.975 mm (0.156 in.)
5 90515-PRP-010 4.000 mm (0.157 in.)
6 90516-PRP-010 4.025 mm (0.158 in.)
7 90517-PRP-010 4.050 mm (0.159 in.)
8 90518-PRP-010 4.075 mm (0.160 in.)
9 90519-PRP-010 4.100 mm (0.161 in.)
10 90520-PRP-010 4.125 mm (0.162 in.)
11 90521-PRP-010 4.150 mm (0.163 in.)
12 90522-PRP-010 4.175 mm (0.164 in.)
13 90523-PRP-000 4.200 mm (0.165 in.)
14 90524-PRP-000 4.225 mm (0.166 in.)
15 90525-PRP-000 4.250 mm (0.167 in.)
16 90526-PRP-000 4.275 mm (0.168 in.)
17 90527-PRP-000 4.300 mm (0.169 in.)
18 90528-PRP-000 4.325 mm (0.170 in.)
19 90529-PRP-000 4.350 mm (0.171 in.)
20 90530-PRP-000 4.375 mm (0.172 in.)
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the installed parts from the secondary shaft. Attachment, 42 mm I.D. 07QAD-P0A0100
1. Install the thrust needle bearing (A), the needle bearing (B), 1st gear (C), the thrust needle bearing
(D), the 40 x 51.5 mm thrust washer (E), the 1st/3rd
clutch (F), and the 3rd gear collar (G) on the
secondary shaft (H). Do not install the O-rings
during inspection.
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Page 1245 of 2893

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THRUST WASHER, 37 x 58 mm
No. Part Number Thickness Special Tools Required
14-32214-322Shafts and Clutches
Secondary Shaft 2nd Gear Axial
Clearance Inspection (cont’d)
Secondary Shaft 1st Gear Axial
Clearance Inspection
L
24x1.25mm
29N·m(3.0kgf·m,22lbf·ft)
K
J I
G
F
E
D
C
B A
H
3. If the clearance is out of standard, remove the 37 x 58 mm thrust washer and measure its
thickness.
4. Select and install a new thrust washer, then recheck.
1 90511-PRP-010 3.900 mm (0.154 in.)
2 90512-PRP-010 3.925 mm (0.155 in.)
3 90513-PRP-010 3.950 mm (0.156 in.)
4 90514-PRP-010 3.975 mm (0.156 in.)
5 90515-PRP-010 4.000 mm (0.157 in.)
6 90516-PRP-010 4.025 mm (0.158 in.)
7 90517-PRP-010 4.050 mm (0.159 in.)
8 90518-PRP-010 4.075 mm (0.160 in.)
9 90519-PRP-010 4.100 mm (0.161 in.)
10 90520-PRP-010 4.125 mm (0.162 in.)
11 90521-PRP-010 4.150 mm (0.163 in.)
12 90522-PRP-010 4.175 mm (0.164 in.)
13 90523-PRP-000 4.200 mm (0.165 in.)
14 90524-PRP-000 4.225 mm (0.166 in.)
15 90525-PRP-000 4.250 mm (0.167 in.)
16 90526-PRP-000 4.275 mm (0.168 in.)
17 90527-PRP-000 4.300 mm (0.169 in.)
18 90528-PRP-000 4.325 mm (0.170 in.)
19 90529-PRP-000 4.350 mm (0.171 in.)
20 90530-PRP-000 4.375 mm (0.172 in.)
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the installed parts from the secondary shaft. Attachment, 42 mm I.D. 07QAD-P0A0100
1. Install the thrust needle bearing (A), the needle bearing (B), 1st gear (C), the thrust needle bearing
(D), the 40 x 51.5 mm thrust washer (E), the 1st/3rd
clutch (F), and the 3rd gear collar (G) on the
secondary shaft (H). Do not install the O-rings
during inspection.
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Page 1246 of 2893
Î
µµ
Standard: 0.04 0.12 mm (0.002 0.005 in.)
14-323
07QAD-P0A0100
JI
A
B 40 x 51.5 mm
THRUST WASHER A
B
2. Install the idler gear (I), then install the ball bearing
(J) on the idler gear using the 42 mm I.D.
attachment and a press.
3. Install the conical spring washer (K) and the locknut (L), then tighten the locknut to 29 N·m (3.0 kgf·m,
22 lbf·ft).
4. Turn the secondary shaft assembly upside down, and set the dial indicator (A) on 1st gear (B). 5. Lift 1st gear (A) up while holding the secondary
shaft, and use the dial indicator (B) to read the 1st
gear axial clearance.
6. Measure the 1st gear axial clearance in at least three places while moving 1st gear. Use the
average as the actual clearance.
(cont’d)
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Page 1247 of 2893

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THRUST WASHER, 40 x 51.5 mm (’06 Model)
No. Part Number Thickness
THRUST WASHER, 40 x 51.5 mm (’07-09 Models) No. Part Number Thickness
14-32414-324Shafts and Clutches
Secondary Shaft 1st Gear Axial
Clearance Inspection (cont’d)
Idler Gear Shaft Removal and
Installation
D
C
B A
7. If the clearance is out of standard, remove the 40 x 51.5 mm thrust washer and measure its
thickness.
8. Select and install a new thrust washer, then recheck.
1 90503-PRP-000 4.80 mm (0.189 in.)
2 90504-PRP-000 4.85 mm (0.191 in.)
3 90505-PRP-000 4.90 mm (0.193 in.)
4 90506-PRP-000 4.95 mm (0.195 in.)
5 90507-PRP-000 5.00 mm (0.197 in.)
6 90508-PRP-000 5.05 mm (0.199 in.)
1 90503-RCT-000 4.80 mm (0.189 in.)
2 90504-RCT-000 4.85 mm (0.191 in.)
3 90505-RCT-000 4.90 mm (0.193 in.)
4 90506-RCT-000 4.95 mm (0.195 in.)
5 90507-RCT-000 5.00 mm (0.197 in.)
6 90508-RCT-000 5.05 mm (0.199 in.)
9. After replacing the thrust washer, make sure the clearance is within standard.
10. Disassemble the installed parts from the secondary shaft. 1. Remove the snap ring (A), the cotter retainer (B),
and the cotters (C). Do not distort the snap ring.
2. Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.
3. Check the snap ring and the cotter retainer for wear and damage. Replace them if they are worn,
distorted, or damaged.
4. Install the idler gear and the idler gear shaft in the reverse order of removal.
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Page 1248 of 2893

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THRUST WASHER, 40 x 51.5 mm (’06 Model)
No. Part Number Thickness
THRUST WASHER, 40 x 51.5 mm (’07-09 Models) No. Part Number Thickness
14-32414-324Shafts and Clutches
Secondary Shaft 1st Gear Axial
Clearance Inspection (cont’d)
Idler Gear Shaft Removal and
Installation
D
C
B A
7. If the clearance is out of standard, remove the 40 x 51.5 mm thrust washer and measure its
thickness.
8. Select and install a new thrust washer, then recheck.
1 90503-PRP-000 4.80 mm (0.189 in.)
2 90504-PRP-000 4.85 mm (0.191 in.)
3 90505-PRP-000 4.90 mm (0.193 in.)
4 90506-PRP-000 4.95 mm (0.195 in.)
5 90507-PRP-000 5.00 mm (0.197 in.)
6 90508-PRP-000 5.05 mm (0.199 in.)
1 90503-RCT-000 4.80 mm (0.189 in.)
2 90504-RCT-000 4.85 mm (0.191 in.)
3 90505-RCT-000 4.90 mm (0.193 in.)
4 90506-RCT-000 4.95 mm (0.195 in.)
5 90507-RCT-000 5.00 mm (0.197 in.)
6 90508-RCT-000 5.05 mm (0.199 in.)
9. After replacing the thrust washer, make sure the clearance is within standard.
10. Disassemble the installed parts from the secondary shaft. 1. Remove the snap ring (A), the cotter retainer (B),
and the cotters (C). Do not distort the snap ring.
2. Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.
3. Check the snap ring and the cotter retainer for wear and damage. Replace them if they are worn,
distorted, or damaged.
4. Install the idler gear and the idler gear shaft in the reverse order of removal.
08/08/21 14:51:25 61SNR030_140_0326
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DYNOMITE -2009-