when the seal installer bottoms out.

J-50818

Apply a light coat of CVT fluid to the
converter seal’s lip surfaces.

Figure 58

3. Do not install either differential side oil seal at this time. They are to be installed during
step 11 (page 41).
NOTE: Both differential side oil seals are to be installed after the CVT has been
completely assembled.

CVT case

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Install / Assemble CVT Internal Parts
1. Install the new select shim(s) in
the CVT case outer race bore (see
Figure 59).


Make sure the race bore is thoroughly
clean before shim installation.
CAUTION:
 Never re-use an old shim.
 All new shims are to be installed
in the CVT case outer race bore.
Never install the new shim(s) in
the converter housing race bore.
Figure 59

2. Install the new outer races using
Race Installer J-50274 from Tool
Kit J-50255, and Driver handle J-8092
(see Figure 60 and 61).



CVT case

J-8092

Make sure the bores are thoroughly
clean before installing the races.

J-50274

Make sure the races are fully seated.

NOTE: The tools shown in Figure 60 and
61 are similar but may not look exactly
the same as J-50274 and J-8092.

Figure 60

Converter
housing

J-8092

J-50274

Figure 61

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Allen head bolt

3. Install the new oil pump using the three
(3) Allen™ head bolts (see Figure 62).


Finger tighten the Allen™ head bolts
at this time.

Oil pump

Figure 62

4. Put in place a new O-ring on the fitting
bolt, and then coat it with CVT fluid (see
Figure 63).

New
O-ring

Figure 63

5. Install the oil pump fitting bolt finger tight
(see Figure 64).
6. Torque the three (3) Allen™ head bolts
and fitting bolt.


Allen™ head bolts torque:
17.6 - 20.6 N•m (1.79 - 2.1 kg-m,
13.0 - 15.2 ft lb)



Fitting bolt torque: 26.0 - 30.0 N•m
(2.65 - 3.06 kg-m, 19.2 - 22.1 ft lb)

Fitting
bolt

Figure 64

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7. Apply petroleum jelly or equivalent to the
oil pump cover’s lathe cut seals (see
Figure 65).

Lathe cut
seals

NOTE: The existing seals are being
reused. They are not being replaced.

Figure 65

8. Install the oil pump cover and third baffle
plate with related bolts finger tight (see
Figure 66).


Do not force the oil pump cover in
place.



Make sure the oil pump cover is fully
seated before installing the bolts.



Do not torque these bolts at this time.

Oil pump
cover, third
baffle plate,
and bolts
Figure 66

9. Install the second baffle plate and “L”
bracket with related bolts finger tight
(see Figure 67).

Second baffle
plate and bolts

10. Torque the bolts in step 8 and 9 in the
following order:
a. Second baffle plate bolts: 5.9 N•m
(0.6 kg-m, 52.2 in lb)
b. “L” bracket bolts: 25.5 N•m
(2.6 kg-m, 19 ft lb). Torque 1 , and
then 2 .

2
1

c. Oil pump cover and third baffle
plate bolts torque: 19.0 - 20.6 N•m
(1.9 kg-m, 14 ft lb)
Figure 67
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“L” bracket
and bolts

11. Install a new snap ring in the new oil
pump (see Figure 68 and 69).

Figure 68

Snap ring

Figure 69

Thrust washer
12. Install the existing thrust washer onto
the oil pump cover (see Figure 70).


Use petroleum jelly or equivalent to
hold the thrust washer in place.



Make sure the tabs fit into the holes.

Tabs
Figure 70

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Drive sprocket
Chain
Driven sprocket

13. Install the drive sprocket, driven
sprocket, and chain as an assembly (see
Figure 71, 72, and 73).

Figure 71



Raised
edge up

Make sure the raised edge on the
drive sprocket is facing up (see
Figure 72).

Figure 72

14. Expand the snap ring with a suitable tool,
and then push down on the driven
sprocket until it bottoms out (see
Figure 73).

Snap ring
ends

Driven
sprocket

15. Release the snap ring, and then pull up
on the driven sprocket until the snap ring
snaps and locks in its groove.
NOTE: A click sound is heard when the
snap ring locks in place.
CAUTION: Make sure the driven
sprocket is locked in place.
Figure 73

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16. Install the first baffle plate with related
nuts (see Figure 74).


Nuts torque: 5.9 N•m (0.6 kg-m,
52.2 in lb)

First baffle
plate nuts

CAUTION: To avoid rounding off
these nuts, it is best to use a 3/8 drive
6-pt 10 mm socket.

Figure 74

17. Install a new O-ring on the input shaft
(see Figure 75).


O-ring

Apply CVT fluid to the O-ring and
O-ring groove before installing.

Figure 75

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18. Install the differential assembly into the
CVT case (see Figure 76).

Differential
assembly

CAUTION: Be careful not to damage
gear teeth and bearings when fitting
the differential assembly in place.


Thoroughly clean the differential
assembly before installing.



Oil the bearings and gear teeth with
CVT fluid before installing.
Figure 76

19. Install the new reduction gear assembly
into the CVT case (see Figure 77).

Reduction gear
assembly

CAUTION: Be careful not to damage
gear teeth and bearings when fitting
the reduction gear assembly in place.


Make sure the reduction gear
assembly is thoroughly clean before
installing.



Oil the bearings and gear teeth with
CVT fluid before installing.

Figure 77

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Install CVT Fluid Filter and Filter cover

Filter with
seal, and
O-ring

1. Install a new filter with grommet seal and
new O-ring (see Figure 78).


Make sure the areas where the filter
and O-ring fit are thoroughly clean.



Apply CVT fluid to the grommet seal
and O-ring before installing.



Figure 78 does not show the
grommet seal. It is fitted to the
bottom side of the filter.
Figure 78

2. Install the filter cover (see Figure 79).


Make sure the filter cover is
thoroughly clean on the inside
before installing.



Filter cover bolts torque: 4.2 N•m
(0.43 Kg-m, 37.2 in lb)

Filter cover
and bolts

Figure 79

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Install Converter Housing to CVT Case
IMPORTANT:
Have the converter housing ready for installation prior to applying sealant.
Before sealant application, make sure the mating surfaces are clean from oil, dirt, old
sealant, etc.
CAUTION: Do NOT use sanding discs or similar abrasive tools. Use brake spray or
equivalent solvent and lint-free towels only.


Make sure the brake spray or solvents used are compatible with local regulations.

1. Apply one continuous 2.0 mm (0.08 inches) diameter bead of pink colored Loctite 5460
Sealant or equivalent (see footnote (4) and (6) in PARTS INFORMATION) as shown in
Figure 80.
NOTE:
 Start applying sealant where shown, making sure that the starting point and the
ending point are about the middle between the bolt holes.
 Overlap both ends of the bead by 3-5 mm (0.12-0.20 inches).
 Make sure to apply sealant around the central bolt hole.

Also apply sealant
around this bolt hole

Figure 80

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2. Install the converter housing onto the CVT case:


Install new bolts from the parts kit.

a. Torque the first six (6) bolts with symbol

in numbered sequence (see Figure 81).

b. Torque the remaining bolts with symbol

in numbered sequence (see Figure 81).

 Use a short socket on the bolts indicated by this symbol:
 All bolts are 30 mm in length.
 Bolts torque: 45.0 N•m (4.6 kg-m, 33.2 ft lb)
IMPORTANT: Make sure to torque the bolts in the sequence shown in
Figure 81 ONLY.

22
20
20

21
21

19
19

77

23

18
18

8
99

17
17

1
10
10

16
16

11

15
15
14
14

13
13

12
12

Figure 81

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Install New Control Valve Assembly (Valve Body) and Miscellaneous
CAUTION: Handle the valve body carefully.

1. Install a new lip seal (see Figure 82).

Lip seal

NOTE: Apply a small amount of
petroleum jelly onto the lip seal to
keep it in place.

Figure 82

2. Move the wiring harness out of the way
(see Figure 83).

44 mm bolt

3. Carefully put the new valve body in place,
and then secure with its nine (9) mounting
bolts (see Figure 83).


Bolts torque 8.0 N•m (0.81 Kg-m,
70.8 in lb).

Wiring harness
Figure 83

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4. Connect the wiring harness connector (see
Figure 84).

Wiring harness
connector
Figure 84

5. Install the oil strainer bracket with its
two (2) bolts. See Figure 85.


Bolts torque: 8.0 N•m (0.81 Kg-m,
70.8 in lb).

6. Install the fluid temp sensor bracket with
its two (2) bolts. See Figure 85.