MANUAL TRANSMISSION UNIT > REMOVAL

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

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

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

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

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

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

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

   SST

   09817-16011  
   

1. Remove the 9 bolts.
   

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

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

1. Remove the 4 bolts from the extension housing.
   

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

1. Remove the bolt and driven gear.
   

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

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

1. Remove the bolt from the shift lever housing.
   

2. Remove the 8 bolts.
   

3. 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.
   

1. Remove the magnet from the extension housing.
   

1. Remove the receiver pipe from the extension housing.
   

1. Remove the bolt and oil receiver.
   

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

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

3. Remove the restrict pin from the extension housing.
   

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

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.
   

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

1. Using a snap ring expander, remove the snap ring from the transmission case.
   

1. Using a snap ring expander, remove the snap ring from the transmission case.
   

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.
   

1. Fix the intermediate plate in a vise.
   

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

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

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

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

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

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

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

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

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

2. 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.
   

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

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

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

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

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

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

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

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

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

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

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.)
   

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

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

1. Remove the thrust washer from the counter gear.
   

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

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

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

2. Remove the shift fork from the shift arm.
   

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

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

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.)
   

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

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.)
   

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

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

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

2. 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)
   

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

2. 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.