GEARBOX AND 4x4 COUPLING UNIT )GENERAL

During assembly/installation, use the torque values and service products as shown in the diagram(s).

Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION for complete procedure.

Always drain the gearbox before working on it. To remove the gearbox, the engine removal is necessary. Refer

to ENGINE REMOVAL AND INSTALLATION. Remove the drive and driven pulley and CVT air guide. (Refer

to CVT.)

Caution: Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) Must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed.

Overview

1 – Right housing2 – Center housing3 – Left housing4 – Output shaft5 – Bearing cover6 – Countershaft7 – Shift shaft 8 – Actuator

GEARBOX OIL CHANGE

Draining Procedure

NOTE: Prior to changing the oil, ensure the vehicle is on a level surface. The oil change should be done with a warm engine.Caution: The gearbox oil can be very hot.

1. Place a drain pan under the gearbox drain plug area.2. Clean the drain plug area and remove the magnetic drain plug

no. 42 with its sealing ring no. 43 to drain the gearbox oil.3. Remove oil filler screw no. 44 including its o-ring no. 45.

CAUTION : Pay attention not to loosen the o-ring on the drain plug screw.

4. Wait a while to allow oil flow out of gearbox.

1 – Magnetic drain plug2 – Sealing ring3 – Oil filler screw

5. Dispose of the gearbox oil according to your local environmental regulations.

Oil InspectionThe oil condition gives information about condition of the teeth inside the gearbox. (See TROUBLESHOOTING.)

1. Clean the magnetic drain plug from metal shavings and dirt.

Presence of debris indicates a failure inside the gearbox. Check the gearbox to correct problem.

2. Change gasket ring no. 43 on the magnetic drain plug if damaged.

3. Replace o-ring no. 45 if brittle, hard or otherwise damaged.

Oil Filling Procedure1. Make sure that magnetic drain plug no. 42 is reinstalled and

tight.2. With the vehicle on a level surface, fill the gearbox through

the oil filler hole with XP-S chaincase oil, XP-S synthetic chaincase oil, or with an equivalent product until the oil reaches the lower threads of the oil filler hole (around 400 mL).

GEARBOX POSTION INDICATOR SWITCHESNote: The gearbox removal is not necessary to reach the gearbox position indicator switches.

Gearbox Position Indicator Switches Removal1. To reach the gearbox position indicator switches no. 41,

remove the rear engine cover.2. Remove screw retaining indicator switch wire.

1 – Gearbox position indicator switches2 – Brown/grey wire3 – White/grey wire4 – Orange/Grey wire

3. Unscrew switch.

Testing the Gearbox Position Indicator SwitchesCheck if gearbox position indicator switches work properly as per following procedure:NOTE: Remove insulating paint to obtain correct readings.

1. Put the gearbox in park, reverse, neutral, high and low position.

2. Use a multimeter to measure the resistance from the indicator switch to the engine ground.

3. Compare the results with the following table.

Shifter Positio

n

Corresponding Switch WiresBrown/Grey

White/Grey

Orange/Grey

L x xH xN x xR xP x x

An “x” indicates the switch is making ground contact, and therefore there should be continuity. (R is close to 0 ohms.)

A blank space indicates the switch is not making contact, and there should be no continuity. (R = infinite)

4. If the indicator switch is good, check the vehicle harness and /or indicator lights.

Gearbox Position Indicator Switches InstallationInstallation of the gearbox position indicator switches is the reverse of the removal procedure. Pay attention to the following details.NOTE: Take care – do not damage shifting indicator switched threads during installation.

1. Carefully apply some Loctite 5910 on the threads of the shifting indicator switches.CAUTION : Do not apply Loctite 5910 on the switch plunger as it will lead to switch malfunction. If all switches are removed, make sure to put the wires back in the correct location.

1 – Gearbox position indicator switches2 – Brown/grey wire3 – White/grey wire4 – Orange/grey wire

2. Spray a layer of electrical insulating paint or varnish over the switches to prevent shorts and corrosion.

4WD INDICATOR SWITCHNOTE : The gearbox removal is not necessary to reach the 4WD indicator switch.

4WD INDICATOR SWITCH Removal 1. To reach the 4WD indicator switch no. 40, remove the rear

engine cover.2. Remove the screw retaining the 4WD indicator switch wire.

1 – 4WD indictor switch

2 – Black/yellow wire for contact to 4WD3 – Actuator4 – Speed sensor

TESTING THE 4WD INDICATOR SWITCH1. Put the vehicle in 2WD mode and measure the resistance from

the 4WD indicator switch (black/yellow wire) to the engine ground.

2. If the resistance is infinite (0L), replace the 4WD indicator switch.

4WD INDICATOR SWITCH InstallationThe installation of the 4WD indicator switch is the reverse of the removal procedure. Pay attention to the following details.NOTE: Take care; do not damage indicator switch threads during installation.

1. Carefully apply some Loctite 5910 on threads of shifting indicator switches.CAUTION: Do not apply Loctite 5910 on the switch plunger, as it will lead to switch malfunction.

2. If all switches are removed, make sure to put the wires back in the right location.

3. Spray a layer of electrical insulating paint or over switches to prevent shorts and corrosion.

OIL SEALS

Oil Seal RemovalReplace oil seals if they are brittle, hard or damaged.A small flat screwdriver can be used to remove most of these oil seals.CAUTION : Avoid scoring housings, bearing cover, shift shaft, and the distance sleeve of the countershaft or output shaft during oil seal removal.

Countershaft Oil SealThe countershaft oil seal no. 47 can be removed without removing gearbox from vehicle. Remove drive and driven pulley and CVT air guide.NOTE: When oil seal is removed, also inspect O-ring no. 31.

1 – Countershaft oil seal2 – Distance sleeve

Shift Shaft Oil SealThe shift shaft oil seal no. 38 can be removed without removing the gearbox from the vehicle.

Remove side panel and the shifting plate from shift shaft to reach the oil seal.

Output Shaft Oil SealRemoval of output shaft oil seal no.46 requires that the rear propeller shaft is separated from the output shaft (refer to DRIVE TRAIN section). The removal of the gearbox or bearing cover is not necessary.NOTE : When oil seal is removed also inspect O-ring no. 4.

1 – Shift oil seal2 – Output shaft oil seal

Inspection

1. Check bearings behind each oil seal for contamination and/or metal shavings.

2. Check the oil seal running surfaces for scratches, and replace if necessary. (Refer to GEARBOX.)

3. Check if the countershaft O-ring no. 31 and the output shaft O-ring no. 4 are brittle, hard or damaged. Replace if necessary.

Output Shaft and Countershaft Oil Seal InstallationThe installation is the reverse of removal procedure. Pay attention to the following details.1. Install output shaft oil seal and countershaft oil seal with the oil

seal installer.

Oil seal installer

1 – Output shaft oil seal2 – Oil seal installer

1 – Countershaft oil seal2 – Oil seal installer

Shift Shaft Oil Seal InstallationUse a suitable tube with the proper diameter to install the shift shaft oil seal.If the gear housing is apart, the oil seal installer and installer handle can be used for shift shaft oil installation.

CAUTION: Oil seal must be installed with sealing lip toward gearbox.

ACTUATORTesting the Actuator

1. Using the multimeter FLUKE 111, check to see if the 2WD/4WD selector works properly.

2. Remove the rear engine cover.3. Unplug actuator connector.4. Turn the ignition key ON.5. Select the 2WD position.

Install the RED probe to the WHITE wire connector, and the BLACK probe to the WHITE/BLACK wire connector. The obtained value should be 12 Vdc.

6. Select 4WD position. Install the RED probe to the WHITE/BLUE wire connector

and the BLACK probe to the WHITE wire connector. The obtained value should be 12 Vdc.

7. If the selector is out of specifications, check wires, connectors and replace the selector if necessary.

8. If the selector is good, check the vehicle harness.9. If the vehicle harness is good, replace the actuator no. 39.

Actuator RemovalNOTE: Before beginning servicing the actuator, make sure the vehicle is in 4WD position. There is no need to remove engine from vehicle.

1. Remove the RH footrest and the rear engine cover. (Refer to BODY.)

2. Unplug actuator connector.

3. Place a drain pan actuator.4. Unscrew actor bolts.5. When all actor bolts are removed, pull the actuator out of

housing.

Actuator Installation1. Apply a small amount of Super Lube grease on actuator O-ring.

1 – Actuator o-ring

2. Verify if coupling fork no. 10 is in 4WD position. The coupling fork should be positioned toward the front of vehicle.

3. Align the actuator fork with the pin on coupling fork no. 10. Then push the actuator in the housing. See the following diagram to position the actuator correctly.

4. Rotate the actuator counterclockwise until it orients itself to the mounting position.

CAUTION : Do not cut or break the actuator O-ring.5. Install all actuator bolts, then torque them to 25 N/m.6. Connect actuator.7. Lift the front of vehicle.8. Turn front wheels. The front propeller shaft should not turn – the

PARK position must be selected.9. If the front propeller shaft turns, the actuator is not installed

correctly. Remove the actuator and reinstall it.10. Place the ignition switch to the ON position, and select the 2WD

position.11. Turn the front wheel again. The front propeller shaft should turn

easily. If the front propeller shaft does not turn, the actuator is not installed correctly. Remove the actuator and reinstall it.CAUTION : Refill the missing gearbox oil. (Refer to GEARBOX OIL CHANGE.)

12. Install all other removed parts.

OUTPUT SHAFT AND COUPLING MECHNISMRemove the gearbox. (Refer to GEARBOX.)Before removing the right housing and output shaft no. 1, measure the backlash on the output shaft. This measure will indicate if the output shaft adjustment is necessary.

Output Shaft Backlash Procedure

1. Engage the PARK position on the gear shaft to block the gearbox.

2. Remove: Bearing cover with oil seal

1 – Bearing sleeve2 – Oil seal

Distance sleeve O-ring

1 – Distance sleeve2 – O-ring

3. Install the backlash measurement tool at the end of output shaft.

4. From the center of the tool bolt, measure 47mm and place a mark on the tab.

1 – Backlash measurement tool2 – Mark on tabA – 47mm

5. Position the head of the dial indicator, against the tab at a 90° angle and on the line. Then, gently rotate the output shaft. This reading gives the backlash measurement.

Refer to the following table for backlash specifications.Output Shaft BacklashNew 0.10 to 0.20 mm

Service Limit 0.25 m

6. If the backlash is not within the specifications, remove the output shaft and select the next larger or smaller shim to meet the specifications.NOTE: Use next lager shim to increase backlash and next small shim to reduce backlash.

Output Shaft Backlash Removal1. Remove the actuator no. 39.2. Remove the bearing cover with oil seal.3. Unscrew all bolts retaining the right housing to the center

housing.4. To remove right housing, use 2 big screwdrivers.

POSITION FOR FLAT SCREWDRIVER

POSITION FOR BIG FLAT SCREWDRIVER

5. Remove output shaft.CAUTION : Use a soft hammer to remove output shaft from center housing.

1 – Output shaft2 – Coupling sleeve3 – Soft hammer

6. Remove the coupling sleeve, O-ring, ball bearing, & shim.

1 – Coupling sleeve2 – O-ring 3 – Ball bearing4 – Shim

7. Remove the ball bearing and thrust washer

1 – Ball bearing

2 – Thrust washer

8. Set the screw, pin and coupling fork.

1 – Set screw2 – Pin 3 – Coupling fork

Output Shaft Backlash Inspection1. Check output shaft no. 1 and its gear for cracks, bend, pitting

or other visible damages.2. Check output shaft splines for wear or other damages.

CAUTION : Always replace output shaft and bevel gear shaft at the same time. Adjust these components upon replacement.

3. Check if the output shaft bearings no. 3 and no. 7 turn freely and smoothly. Replace if necessary.

4. Replace oil seal no. 46 if brittle, hard or damaged.5. Replace O-rings no. 4 and no. 8 if brittle, hard or damaged.6. Check splines of coupling sleeve no. 9 for wear or other

damages.

1 – Inspect splines

7. Measure the coupling sleeve groove width.

A – Groove width

Coupling Sleeve Groove WidthNew 5.25 to 5.35 mm

Service Limit 6.50 m

8. Check the thickness of the coupling fork claw.

1 – Coupling fork 2 – Micrometer

Coupling Sleeve Groove Thickness

New 4.95 to 5.05 mmService Limit 4.80 mm

9. Clean the housing split surface and especially the bearing areas from metal particles or other contamination.

Output Shaft Backlash Installation1. Install the shim no.6, bearing no. 7, O-ring no. 8 and coupling

sleeve no. 9 onto the output shaft.2. Install the thrust washer no. 2 and ball bearing no. 3. (The O-

ring no. 4 and distance sleeve no. 5 are not installed at this time.)

3. Place the output shaft into the center housing.4. Use soft hammer to put bearing exactly in place against

center housing.

1 – Soft hammer

5. Clean the bearing cover location then attach bearing cover with oil seal to the housing.

6. Temporarily install the right housing with the four (4) M8 TORX screws beside the bearing seats.NOTE: Prior to tightening the TORX screws, tap on the gear end of output shaft with a soft hammer to take up all gear free play.

7. Verify the output shaft backlash, and adjust as required. (Refer to OUTPUT SHAFT BACKLASH PROCEDURE.)

8. If the backlash is within specifications, remove the dial indicator, backlash measuring tool, bearing cover and right housing.NOTE : Install coupling fork, pin and set screw in right housing before applying sealant to the mating surface.

1 – Coupling fork2 – Pin3 – Set screw

9. Clean all metal components in a solvent.10. Housing mating surfaces are best cleaned using a

combination of Loctite chisel (gasket remover) and a brass brush. Brush the first pass in one direction, then make the final brushing perpendicular (90°) to the first pass cross (hatch).CAUTION: Do not wipe with rags. Use a new clean hand towel only.IMPORTANT : When beginning the application of the sealant, the assembly and the first torquing should be done within 10 minutes. It is suggested to have all you need on hand to save time.

11. Use Lotite 5910 on mating surfaces.12. Use a plexiglass plate and apply some sealant on it. Use a

soft rubber roller (50-75 mm), available in arts products suppliers for printing.

13. Roll the sealant to get a thin uniform coat on the plate and spread as necessary. When ready, apply the sealant on housing mating surfaces. Do not apply in excess as it will spread out inside housing.NOTE : It is recommended to apply this specification without lumps. If you do not use the roller method, you may use your finger to uniformly distribute the sealant (using a finger will not affect the adhesion).

14. Install all other screws on right housing, then the O-ring no. 4 and the distance sleeve no. 5 on end of output shaft. The bore

of distance sleeve has to face the engine.

1 – O-ring2 – Distance sleeve

NOTE : To install the right housing, align the coupling fork no. 10 with the groove in the coupling sleeve no. 9.

15. Torque the four (4) M8 TORX screws in a crisscross sequence by hand, and retighten to 25 N/m.

16. Tighten all M6 TORX screws to 10 N/m.17. Before installing bearing cover, apply Loctite 5910 on the

housing and Super Lube grease on seal.18. Install the actuator. (Refer to ACTUATOR.)19. Complete final assembly.

GEARBOXGearbox Removal

1. Remove engine from vehicle and place it on footrest support. (Refer to ENGINE REMOVAL AND INSTALLATION.)

2. Drain the gearbox. (Refer to GEARBOX OIL CHANGE.)3. Unscrew the three (3) nuts attach the gearbox to the engine.4. Pull gearbox to separate it from engine.

Gearbox DisassemblyNOTE : During gearbox disassembly, inspect the condition of each part closely.

1. Remove the output shaft. (Refer to OUTPUT SHAFT AND COUPLING MECHANISM.)

2. Push the bevel gear no. 11 with a pin lightly down and measure the axial clearance of the bevel gear with a feeler gauge.NOTE: Bevel gear axial clearance must be measured before separating the center and left housings.

1 – Bevel gear

Bevel Gear Axial ClearanceNew 0.02 to 0.15 mm

Service Limit 0.19 mm

3. Unscrew the left housing screws.4. Place the left housing on a wood stand, with the center

housing pointing upwards.5. Using two big flat screwdrivers, lift the center housing. See the

following diagrams for screwdriver positioning.6. Remove center housing completely.

7. Remove the shift shaft assembly.

1 – Shift shaft assembly8. Remove the shift fork shaft9. Disengage the shift fork from shift drum

1 – Shift fork shaft2 – Shift fork3 – Shift drum

10. Remove the bevel gear shaft with low range gear assembly and thrust washer.

1 – Bevel gear2 – Low range gear3 – Thrust washer

11. Remove the sliding gear with shift fork

1 – Sliding gear2 – Shift fork

12. Remove the thrust washer, needle bearing and reverse gear

1 – Thrust washer2 – Needle bearing3 – Reverse gear

13. Remove the thrust washer CVT side

1 – Thrust washer CVT side

14. Remove the countershaft no. 18 with low range gear and high range gear assembly.

1 – Countershaft2 – Low range gear3 – High range gear

15. Insert a flat screwdriver in the slot of index lever. 16. Turn screwdriver clockwise and remove shift drum.

1 – Index level2 – Shift drum

17. Continue by removing the following: Parking lock lever

1 – Parking lock level

Index lever with washer, step ring and spring

1 – Index lever2 – Washer3 – Step ring

Index spring Support flange no. 37.

18. To remove intermediate gear no. 23 and needle bearing 22, use a press bench to push out the intermediate gear shaft no. 21.

PRESS SHAFT IN THE DIRECTION INDICATED BY THE ARROW.19. Remove the intermediate gear shaft.20. Remove the left housing.

Bearing Removal in HousingNOTE: If necessary, heat the housing up to 100℃ before removing

ball bearings or needle bearings.CAUTION: Clean oil, outside and inside, from housing before heating. Always support gearbox housings properly when ball bearings or needle bearings are removed. Housing damages may occur if this procedure is not performed correctly.

1. To remove the bevel gear needle bearing, use a punch.

1 – Bevel gear needle bearing2 – Punch3 – Center housing

2. To remove the ball bearings of bevel gear no. 36 and needle bearing of countershaft no. 33, use a blind hole bearing puller.

3. To remove the countershaft ball bearing, remove the screw and intermediate gear shaft, and push with a suitable puller from the outside inward.

1 – Screw2 – Intermediate gear shaft3 – Ball bearing countershaft4 – Bevel gear ball bearing

General Gearbox InspectionAlways look for the following when inspecting gearbox components:

Gear teeth damage Worn or scoured bearing surfaces Worn or scoured shift fork Worn or scoured shift fork shaft Rounded engagement dogs and slots Bent shift forks Bent shift fork shaft Worn shift fork engagement pins Worn tracks on shift drum Worn shift fork engagement groove Worn splines on shafts and gears.

Bearing Inspection1. Check if bearings no. 34 and no. 36, as well as needle

bearings no. 33 and no. 35 turn freely and smoothly.2. Check all bearings, bearing points, tooth flanks, taper grooves

and annular grooves. Annular grooves must have sharp edges.

Shift Forks Inspection1. Check both shift forks for visible damage, worn or bent shift

fork claws.2. Measure the shift fork claw thickness.

1 – MicrometerA – Shift fork claw thickness

3. Measure the shift fork no. 25 for high gear shifting.

Shift Fork Claw Thickness (High Gear Shifting )

New 4.80 to 4.90 mmService Limit 4.70mm

4. Measure the shift fork no. 26 for low/reverse gear shifting.

Shift Fork Claw Thickness(Low/Reverse Gear Shifting)

New 5.10 to 5.20 mmService Limit 5.0 m

5. Measure shift fork pins.

1 – MicrometerA – Shift fork pin diameter

Shift Fork Pin DiameterNew 6.920 to 6.970 mm

Service Limit 6.850 mm

Shift Drum Inspection1. Check shift drum tracks for scouring or heavy wear, like

rounded engagement slots.2. Replace isolating washer no. 27 if there are signs of wear or

visible damages.

1 – Track for the low/reverse gear shift fork2 – Track for the high gear shift fork3 – Isolating washer on the shift drum

Levers Inspection1. Check parking lever no. 29 for cracks or other damages.2. Index lever with roller no. 28 must move freely.

Gears InspectionNOTE : Replace gears only together with the corresponding meshing gears. Always replace circlips and use special pliers to install them.

1. Measure the width of shift fork engagement groove.

1 – Main gear 2 – CaliperA – Width for engagement of shift fork

2. Measure gear no. 20 for high gear shifting.

Width of Shift Fork Engagement Groove

(High Gear Shifting)New 5.00 to 5.10 mm

Service Limit 5.20 mm

3. Measure gear no. 15 for low/reverse gear shifting.

Width of Shift Fork Engagement Groove

(Low/Reverse Gear Shifting)New 5.30 to 5.40 mm

Service Limit 5.5 mm

4. Check free pinion no. 14, no. 16, no.19 and no. 23 for wear.

1 – Micrometer2 – Free pinion

Diameter Free PinionNew 29.000 to 29.013 mm

Service Limit 29.015 mm

Shafts Inspection1. Check shaft no. 30 for worn splines and gears.2. Check intermediate shaft for wear.

1 – Intermediate gear bearing

Intermediate Gear Shaft

New 24.979 to 25.00 mm

Service Limit 24.977

3. Check countershaft for wear.

1 – MAG side2 – Free pinion bearing3 – CVT side

Countershaft Service limit

MAG Side 17.990 mmFree Pinion

Bearing 24.970 mmCVT side 24.970

4. Check bevel gear shaft.

1 – Free pinion bearings

Bevel Gear Shaft Service Limit

Free Pinion Bearing 24.984 mm

Shims InspectionNOTE: Always replace shim by a new one with the same thickness, when reassembling the gearbox with existing output shaft no. 1 and bevel gear shaft no. 11.

1 – Thrust washer for adjusting the bevel gear on center housing side2 – Area where wear signs appear3 – Thickness of the washer

Bevel Gear AdjustmentNOTE : Only necessary if backlash and axial clearance of the bevel gear is out of specification or if parts are changed (output shaft, bevel gear shaft or housing).

There are 2 adjustments to perform on the bevel gear:1. Bevel gear backlash on center housing2. Bevel gear axial clearance on left housing.

1. The bevel gear backlash is adjusted by finding the proper thrust washer thickness E as per following illustration.

2. The bevel gear axial clearance is adjusted by finding the proper thrust washer thickness J as per following illustration.

3. Clean mating surface of housing before taking measurements, using a combination of Loctite chisel (gasket remover) and a brass brush. Brush a first pass in one direction then make the final brushing perpendicularly (90°) to the first pass cross (hatch).CAUTION : Do not wipe with rags. Use a new clean hand towel only.

Bevel Gear Backlash ProcedureUse the following course of calculation to determine the theoretical thrust washer thickness D:D = B – C – AB = The distance between the thrust surface of the bevel gear and

the theoretical center of its taper. This is defined by manufacturer and is written on the bevel gear shaft.

This bevel gear reference number could be between -10 and + 10.

1 – Bevel gear2 – Bevel gear reference number

Use following formula to find out value B.

B= ( bevel gear reference number )/ 100 + 37.8For example: Bevel gear reference number = -3.B = (-3/100) + 37.8 = 37.77C = Distance between the shim thrust surface in the center housing and the mating surface to left housing.

1 – Deep gauge – measurement C2 – Thrust washer surface in center housing3 – Mating surface to left housing

A = 2mm nominal thickness of axial needle bearing no. 12.

When the measurements are taken, calculate the theoretical thrust washer thickness D using the formula ( D = B – C – A )

Take the obtained theoretical thrust washer thickness D and choose

the corresponding thrust washer number E according to the following table.

THEORETICAL THRUST WASHER

THICKNESSD

THRUST WASHER NUMBER

E1.20 mm to 1.29

mm 1201.30 mm to 1.39

mm 1301.40 mm to 1.49

mm 1401.50 mm to 1.59

mm 1501.60 mm to 1.69

mm 1601.70 mm to 1.79

mm 1701.80 mm to 1.89

mm 180

NOTE : For example, if the theoretical thrust washer thickness D is 1.53 mm, choose the corresponding thrust washer number 150 E. the thrust washer number 150 represents a nominal value equal to 1.50 mm.

Bevel Gear Axial Clearance ProcedureUse the following course of calculation to determine the theoretical thrust washer thickness I:I = F + G – H – A - EF = Distance between mating surface of left housing to ball bearing

inner race.

1 – Ball bearing inner race2 – Mating surface of left housing3 – Depth gauge

G = Distance between mating surface of center housing and thrust washer surface.

1 – Mating surface of center gear housing2 – Thrust washer surface

H = Distance between thrust surface of bevel gear shaft.

A = 2 mm nominal thickness of axial needle bearing no. 12 .E = the thrust washer number nominal value as found in the BEVEL

GEAR BACKLASH PROCEDURE. For example, thrust washer number 150 represents a value of 1.50 mm.

When the measurements are taken, calculate the theoretical thrust washer thickness I using the formula (I = F + G – H – A – E )Take the obtained theoretical thrust washer thickness I and choose the corresponding thrust washer number J according to the following table.

THEORETICAL THRUST WASHER

THICKNESSI

THRUST WASHER NUMBER

J1.22 mm to 1.31

mm 1201.32 mm to 1.41

mm 1301.42 mm to 1.51

mm 1401.52 mm to 1.61

mm 1501.62 mm to 1.71

mm 1601.72 mm to 1.81

mm 1701.82 mm to 1.91

mm 180

For example, if the theoretical thrust washer thickness I is 1.53 mm, choose the corresponding shim number 150 J.Bevel gear axial clearance of 0.02 to 0.11 mm is included in the above table.

Gearbox AssemblyThe assembly of gearbox is essentially the reverse of disassembly procedure. However, pay attention to the following details.

Bearing Installation in HousingNOTE: Unless otherwise instructed, never use hammer to install ball bearings or needle bearings. Use press machine only.

If necessary heat housings up to 100℃ before installing ball bearings or needle bearings.Caution: Clean oil, outside and inside, from housing before heating.

1. Place new bearing in freezer for 10 minutes before installation.2. Use a suitable installer for installing ball bearings of

countershaft and bevel gear.NOTE: Place gearbox housings on a wood stand before installing bearings no. 34 and no. 36.

3. Install countershaft needle bearing no. 33 with the main shaft needle bearing installer and the installer handle in right housing.

1 – Needle bearing installer2 – Installer handle

1 – Countershaft needle bearing2 – Right housing3 – Needle bearing installer4 – Installer handle

4. Install bevel gear needle bearing no. 35 using the bevel gear needle bearing installer and the installer handle.

1 – Needle bearing installer2 – Installer handle

1 – Bevel gear needle bearing2 – Center housing 3 – Needle bearing installer4 – Installer handle

5. Install new oil seals with the proper installer. (Refer to OIL SEALS.)

Other Gearbox Components1. Fit intermediate gear no. 23 with needle bearing no. 22 on

intermediate gear shaft no. 21.NOTE: Fit gear with collar face to housing side on the intermediate shaft.

1 – Intermediate gear2 – Collar facing housing3 – Needle bearing4 – Intermediate gear shaft

2. Press intermediate gear shaft in the left housing.

1 – Intermediate gear shaft

3. Fit support flange no. 37 in the left housing and install index leverNOTE: Fit step ring into index lever.

1 – Shim 2 – Index lever3 – Step ring4 – Index spring

4. Install parking lock level, teeth showing to countershaft.

1 – Parking lock lever

5. Place thrust washer CVT side on bearing.

1 – Thrust washer CVT side

6. Place reverse gear with needle bearing and thrust washer.NOTE: Check if the screw to secure countershaft bearing is installed.

1 – Reverse gear2 – Needle bearing3 – Thrust washer4 – Countershaft bearing screw

7. Install countershaft with low gear and high gear assembly.

1 – Countershaft2 – Low gear3 – High gear

8. Install a new shim no.17 onto bevel gear shaft, fork side.9. Install bevel gear with sliding gear assembly together with

shift fork.NOTE: If a new bevel gear and output shaft are used, it is necessary to verify the shim adjustment prior to finalizing assembly. (Refer to ADJUSTMENT.) If the existing bevel gear is used, it is mandatory to use a new shim no. 17 with the same thickness, a new needle bearing no. 12 and thrust washer no. 13.

1 – Bevel gear 2 – Sliding gear3 – Shift fork

10. Install a new needle bearing and thrust washer

1 – Needle bearing2 – Thrust washer

11. Insert a flat screwdriver in the slot of the index lever, turn screwdriver clockwise and install shift drum on neutral position as per the following diagram.

1 – Index lever2 – Shift drum3 – Neutral position

1 – Parking stop location2 – Reverse stop location3 – Neutral stop location4 – High gear stop location5 – Low gear stop location

12. Install shift shaft assembly.NOTE: Marks on shift drum/isolating washer and shift shaft must align.

1 – Shift shaft assembly2 – Isolating washer3 – Marks

13. Install shift fork no. 25 then engage both shift fork pins in their corresponding groove on the shift drum.NOTE: Move sliding gears to facilitate engagement of pins inside grooves.

1 – Shift fork pin2 – Sliding gear

14. Install shift fork no. 24.NOTE: Run all gears as a final function check before installing center housing.

15. Now, close the housings by firs cleaning all metal components in a solvent.

16. Gearbox housing mating surfaces are best cleaned using a combination of Loctite chisel (gasket remover) and a brass brush. Brush a first pass in one direction then make the final brushing perpendicular (90°) to the first pass cross (hatch).CAUTION: Do not wipe with rags. Use a new clean hand towel only.IMPORTANT: When beginning the application of the gear housing sealant, the assembly and the first torquing should be done within 10 minutes. It is suggested to have all you need on hand to save time.

17. Use Loctite 5910 on mating surfaces.18. Use a plexiglass plate and apply some sealant on it. Use a

soft rubber (50-75 mm), available in arts products suppliers for printing, and roll the sealant to get a thin uniform coat on the plate (spread as necessary). When ready, apply the sealant on gear housing mating surfaces.

19. Do not apply in excess as it will spread out inside gear housingNOTE: It is recommended to apply this specification without lumps. If you do not use the roller method, you may use your finger to uniformly distribute the sealant (using a finger will not affect the adhesion).

20. Hand-torqued gear housing screws in a crisscross sequence. Repeat procedure, retightening all screws to 10 N/m.

21. Install O-ring no. 31 including distance sleeve no. 32 on countershaft CVT side.CAUTION: Place O-ring including distance sleeve right away. Chamfered bore of distance sleeve has to face the gearbox.

Countershaft end CVT side1 – O-ring2 – Distance sleeve3 – Countershaft end CVT side

Refer to OUTPUT SHAFT AND COUPLING MECHANISM to install these components. Measure the output shaft backlash.