Oil pump, Middle gear, and Crankcase

Oil pump removal and disassembly

1. Remove the strainer cover. Note the wire harness clip position.

2. Remove the oil pump secruing bolts and remove the sprocket cover and oil pump assembly.

CAUTION: Do not attempt to remove the strainer screen as it is permanently fitted onto the pump housing. If the pump housing and/or any parts of the pump are damaged, the pump assembly must be replaced with a new one.

3. Remove the oil pump driven sprocket.

4.      Remove the oil pump cover and rotor assembly.

5.      Remove the pressure relief valve, spring and plunger.

Middle gear

1. Remove the middle driven gear housing holding bolts.

2. Remove the middle driven gear housing assembly and shims.

NOTE: If it is difficult to remove housing assembly, loosen the two crankcase bolts located near the middle driven gear housing.

3. Remove "TORX" screws holding the middle drive gear assembly.

4. Remove the bearing retainers.

Crankcase disassembly

1. Remove the upper crankcase bolts, starting the highest numbered bolt. Turn over the engine and remove the lower crankcase bolts.

CRANKCASE TIGHTENING SEQUENCE

LOWER CASE

UPPER CASE

Tightening Torque

8 mm bolt: 24 Nm (2.4 mkg, 17 ft-lb) O .... 6 mm bolt: 12 Nm (1.2 mkg. 8.7 ft-lb)

Separate the lower case from the engine. Use a soft rubber hammer to carefully separate the crankcase.

Upper crankcase

1. Remove the middle drive gear and damper assqmbly.

2. Remove the transmission main shaft assembly.

3. Remove the A. C. G. shaft cover.

4. Remove the oil spray nozzle.

5. Carefully remove the A. C. G. shaft from the gear.

6. Remove the gear from the chain.

7. Straighten the lock washer tab and remove the bolt securing the starter idle gear shaft. Remove the shaft and starter idle gear.

8. Remove the crankshaft.

Lower crankcase

1.      Remove the dowel pin and "O-ring".

2.      Remove the shift fork guide bar and shift forks. The shift forks are identified by numbers cast on their sides.

3. Remove the bolt securing the shift cam locating pin and remove the stopper plate and locating pin.

1. Shift cam locating pin 2. Neutral switch

4.      Remove the neutral switch.

5.      Pull out the shift cam.

6.      Remove the driven shaft bearing cover holding screws and remove the bearing cover.

7. Remove the 5th wheel gear from the driven shaft and pull out the driven shaft assembly.

1. 5th wheel gear