Install the arm nut with the washer and tighten it.
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Install the reverse selector arm with the slit facing out by aligning the flat surfaces. Install the twelve bolts with the wire guide and side cover stay and tighten them in a crisscross pattern in several steps. If the cover doesn’t install easily, remove it and check the alignment of the switch pin and the shift drum or the switch for damage.Ĭonnect the thermosensor connector. Install the crankcase cover while aligning the switch pin with the shift drum groove properly. Shift the transmission into neutral to align the groove in the shift drum with the lug on the crankcase.Īlign the long end of the gear position switch pin with the ‘‘N’’ mark on the switch plate. Install the two dowel pins and thrust washer. Blow through the oil passages in the rear crankcase cover with compressed air.Īpply liquid sealant to the mating surface (shadowed area) of the rear crankcase cover as shown. Install the gear shaft with the reduction gear.Īpply engine oil to new reverse stopper shaft oil seal and output shaft oil seal lips and install them with the flat side facing out.Ĭlean the mating surfaces of the crankcase and cover. Remove the driven pulley.Īpply molybdenum oil solution to the reduction gear teeth and shaft. Temporarily install the recoil starter driven pulley and bolt and tighten it to seat the flywheel (page 10-7). Install the flywheel on the crankshaft, aligning the key way with the woodruff key. Install the woodruff key into the crankshaft key groove.
![honda atv engine transmission complete assembly honda atv engine transmission complete assembly](https://www.hondaprokevin.com/wp-content/uploads/2016/04/honda-pioneer-1000-5-dct-transmission-problems-utv-848x500.jpg)
Install the washer and needle bearing onto the crankshaft.Ĭlean any oil from the tapered portions of the crankshaft and flywheel. Lubricate the needle bearing with molybdenum oil solution. Install the starter driven gear while turning it clockwise. Hold the flywheel with the special tool and tighten the bolts. Install the starter clutch assembly onto the flywheel and install the bolts. Lubricate the sprag clutch with engine oil and install it into the starter clutch outer with the flange side facing the flywheel side.Īpply locking agent to the starter clutch bolt threads. Measure the starter driven gear boss O.D. Hold the flywheel with the special tool and remove the starter clutch bolts.Ĭheck the starter driven gear teeth and needle bearing for wear or damage. Remove the driven gear while turning it clockwise. Make sure that the starter driven gear turns clock- wise smoothly and does not turn counterclockwise. Remove the sprag clutch from the starter clutch outer.Ĭheck the starter reduction gear and shaft for wear or damage.Ĭheck the starter clutch outer and sprag clutch for abnormal wear or damage. Remove the starter clutch assembly from the flywheel. Thrust washer two dowel pins reduction gear and shaftĠ7725-0040000 or equivalent commercially available in U.S.A. Starter drive gear woodruff key needle bearing washerįor gear position switch removal/installation, see section 20. Remove the flywheel using the special tool. Tighten the pulley bolt by holding the driven pulley using a screwdriver.Īlternator co ver (page 10-5) starter moto r (page 19-4) speed sensor bolts speed sensor, sensor base and O-rings nut, washer and reverse selector arm twelve cover bolts, wire guide and side cover stay thermosensor connector Apply engine oil to the pulley bolt threads and seating surface and install it. Install the recoil starter driven pulley into the flywheel by aligning the wide tooth with the key way.Ĭoat a new O-ring with engine oil and install it onto the driven pulley bolt. Secure the alternator wire with the clamp.Īpply engine oil to a new oil seal and install it into the alternator cover.
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