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Mainshaft
Inspection
NOTE:
Inspect the 43 x 74 mm thrust washer when disassem-
bling the mainshaft assembly or replacing mainshaft
3rd gear and/or 1st/4th clutch assembly.
Lubricate all parts with ATF during assembly.

1. Install mainshaft 3rd gear on the mainshaft using

the special tool and a press as shown.

PRESS

COLLAR

MAINSHAFT

3RD GEAR

ATTACHMENT,
45 x 55 mm I.D.
07MAD-PR90100

3RD GEAR

ATTACHMENT,
45 x 55 mm I.D.
07MAD-PR90100
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2. Assemble the thrust needle bearing, needle bear- 4. Remove the mainshaft bearing from the transmis-
ing, and 4th gear, and install the 43 x 74 mm thrust sion housing (see page 14-199).
washer using the special tool and a press as shown.
5. Assemble the parts below on the mainshaft.
NOTE: Replace the 43 x 74 mm thrust washer, if it
can be installed by pressing with your hand. NOTE: Do not assemble the 0-rings and mainshaft
1st gear.
THRUST
NEEDLE
SNAP RING LOCKNUT
BEARING
WASHER
THRUST
WASHER BALL BEARING
3RD GEAR
REVERSE GEAR
1ST GEAR REVERSE GEAR
DISTANCE DISTANCE COLLAR
4TH GEAR COLLAR

1ST GEAR
NEEDLE
COLLAR
BEARING
CONICAL SPRING
WASHER
THRUST WASHER,
4 3 x 7 4 mm 1ST/4TH 2ND CLUTCH
CLUTCH THRUST WASHER
ATTACHMENT, 2ND GEAR COLLAR
45 x 55 mm I.D.
07MAD - PR90100
THRUST NEEDLE
BEARING TRANSMISSION
HOUSING BEARING

3. Spin mainshaft 4th gear by hand to check for clear-

ance. The clearance is normal if it turns freely with-
out binding.

6. Torque the mainshaft locknut to 29 N-m (3.0 kgf-m,

22 Ibft).

4TH GEAR

LOCKNUT
TRANSMISSION
29 N-m
HOUSING BEARING
(3.0 kgf-m, 22 Ibf-ft)

7. Move the 1st/4th clutch assembly to check the axial

clearances.

(cont'd)
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Mainshaft
Inspection (cont'd)
8. Measure the clearance between the 1st/4th clutch 9. If the clearance is out of tolerance, remove the
guide and 1st gear collar with a feeler gauge. 43 x 74 mm thrust washer, and measure the thick-
ness.
STANDARD: 0 - 0.08 mm (0 - 0.003 in)
NOTE: If the 0.08 mm (0.003 in) feeler gauge can be
NOTE: Take measurements in at least three places, inserted, perform this step.
and use the average as the actual clearance.

CLUTCH GUIDE

1ST GEAR COLLAR

THRUST WASHER,
43 x 74 mm

10. Select and install a new 43 x 74 mm thrust washer,

then recheck.

THRUST WASHER, 43 x 74 mm

1ST/4TH CLUTCH No. Part Number Thickness

ASSEMBLY FEELER GAUGE
1 90431 - PY4 - 000 9.70 mm (0.382 in)
2 90432 - PY4 - 000 9.75 mm (0.384 in)
3 90433 - PY4 - 000 9.80 mm (0.386 in)
4 90434 - PY4 - 000 9.85 mm (0.388 in)
1ST GEAR COLLAR 5 90435 - PY4 - 000 9.90 mm (0.390 in)
THRUST WASHER,
43 x 74 mm 6 90436 - PY4 - 000 9.95 mm (0.392 in)
7 90437 - PY4 - 000 10.00 mm (0.394 in)

11. After replacing the 43 x 74 mm thrust washer, make

sure that the clearance is within the tolerance.

1ST/4TH CLUTCH
ASSEMBLY FEELER GAUGE