

Use a new roll pin (non-reusable).



Punch size: Diameter 3 mm, Length
20 mm or longer.
CAUTION: Use the appropriate size
punch to prevent damage to the roll
pin or detent plate.

Roll pin
Punch

Detent
plate
Manual
shaft
Figure 7Q

NOTE: See Reference # 12 in the KIT
PARTS REFERENCE TABLE.

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Install Powertrain Parts

Tab

Detent spring

1. Install the original manual shaft detent
spring to the CVT case.
IMPORTANT: Locate the tab of the
detent spring to the hole of the CVT case.


16 mm (0.6 inch) long bolt.
 Bolt torque:
6.8 N•m (0.70 kg-m, 60 in-lbs.)
Figure 1R

2. Install the original shim for the input shaft
in the counter bearing bore.
NOTE: See page 36.

Input shaft
shim

Figure 2R

Counter
bearing
3. If the counter bearing is a type “B” or “C”
(ball bearing) skip to step 6 on page 71.
NOTE: Type ”B” counter bearing shown
in Figure 3R. Type “A” is similar.

Figure 3R

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4. If the counter bearing is a type “A” (roller bearing):


If not already done, install the outer race of the roller bearing to the counter bearing
bore of the CVT case.
IMPORTANT: Apply CVT Fluid to the outer race of the roller bearing before
installation.

Type C counter bearing

Input shaft
assembly

Outer race

Counter
bearing bore

Outer race

Figure 4R

Figure 5R

5. If the input shaft assembly is for any reason separated into individual components, see
steps 8e-8g on pages 52-53 to reassemble those parts.

6. Install the input shaft assembly to the
CVT case


Hold the tip of the input shaft so that
the input shaft and the pump cover
remain together.



Confirm that the oil pump cover seats
onto the CVT case completely.

Input shaft

CAUTION: Do not draw the input
shaft assembly down to the case with
the mounting bolts.
Figure 6R

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7. Install the original chain cover and the six
(6) original bolts and then tighten.


16 mm (0.6 inches) long bolt
2 pieces.
 Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lbs.)



0.6 inch
long bolt

1.2 inch
long bolt

30 mm (1.2 inches) long bolt
4 pieces.
 Bolt torque:
27.1 N•m (2.8 kg-m, 20 ft-lbs.)
Figure 7R

Chain cover

8. Rotate the input shaft by hand to confirm
that the shaft rotates freely.
Sleeve
9. Install the sleeve to the reverse brake
tube.


Use a new sleeve (non-reusable).



Apply CVT Fluid to the sleeve before
installation.

NOTE: See Reference # 20 in the KIT
PARTS REFERENCE TABLE.

Figure 8R

10. Install the reverse brake tube to the CVT
case.


16 mm (0.6 inches) long bolt.
 Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lbs.)

2 Bolts

CAUTION: Insert the tube to the CVT
case vertically and evenly to avoid
damages to the sleeve.
Figure 9R

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Parking
rod
11. Connect the parking rod to the detent
plate as shown in Figure 10R.

Detent
plate

Figure 10R

12. Rotate the detent plate until the detent is in the “D” position (see Figure 11R).


The detent spring position shall be on the second left concave of the detent plate.

Parking
rod

D

N

R

P

Figure 11R

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13. Install the oil pump chain onto the oil pump sprocket and the drive sprocket and then
lower onto the oil pump shaft (driven sprocket) (Figure 12R).
14. Expand the snap ring with a suitable tool (Figure 12R), and then push down on the
driven sprocket until it bottoms out.
15. Release the snap ring and then pull up on the driven sprocket until the snap ring locks
into its groove (Figure 12R).
NOTE: A click sound can be heard when the snap ring locks in place.
Driven sprocket
Sprockets
and chain

Snap ring

Figure 12R

16. Install the original thrust bearing onto the
drive sprocket.
IMPORTANT: Install the thrust bearing
with the exposed bearings facing up.
Drive sprocket

Figure 13R

17. Rotate the input shaft by hand to confirm
that the chain, pump and shaft rotate
freely.
18. Install the new O-ring onto the input
shaft.

Thrust bearing

Input shaft



Use a new O-ring (non-reusable).



Apply CVT Fluid to the O-ring before
installation.

NOTE: See Reference # 7 in the KIT
PARTS REFERENCE TABLE.

O-ring
Figure 14R

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19. Install the CVT case O-ring (oval O-ring)
to the CVT case.


Use a new oval O-ring (non-reusable).



Apply CVT Fluid to the O-ring before
installation.

NOTE: See Reference # 11 in the KIT
PARTS REFERENCE TABLE.
O-ring
Figure 15R

20. Install the lip seal to the CVT case.


Use a new lip seal (non-reusable).



Apply CVT Fluid to the lip seal before
installation.

NOTE: See Reference # 10 in the KIT
PARTS REFERENCE TABLE.
Lip seal
Figure 16R

21. Confirm that both seals are seated in their groves.


Use petroleum jelly to help hold the seals in place.

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22. Replace the two machine cut seals (Ring Seals) of the reduction gear assembly, shown
in Figure 17R and then center them in their grooves.


Confirm that the Ring Seals are not protruding in any direction.

CAUTION: These seals are VERY delicate. Handle with care.
NOTE: See Reference # 21 in the KIT PARTS REFERENCE TABLE.
Reduction
gear assembly
Machine cut
seals

Figure 17R

CAUTION: in the following step use extreme care when installing the final drive and
reduction gear assembly.


The machine cut seals are VERY delicate and will damage easily if forced.



The reduction gear assembly should seat without any additional force.



If the reduction gear assembly does not seat, remove it and confirm that machine cut
seals are in place and centered in their grooves.

Thrust bearing

23. Confirm that the thrust bearing is in place
in the bottom of the reduction gear
assembly bore.
Reduction gear
assembly bore
Figure 18R

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24. Install the final drive and reduction gear
assembly together into the CVT case.


If the reduction gear assembly does
not seat, remove it and confirm that
machine cut seals are in place and
centered in their grooves.
Final drive
Figure 19R

25. Rotate the final drive by hand to confirm
that it rotates freely.

Install the Torque Converter Housing
Torque converter
housing
Thrust washer
1. Place the original thrust washer on the
torque converter housing.


Apply petroleum jelly to the mating
surface side of the washer to hold the
washer on the converter housing.

NOTE: Both sides of the thrust washer
are the same, orientation is not critical.

Figure 1S

2. Remove any remaining CVT fluid on the sealing surfaces of the torque converter
housing and the CVT case.
NOTE: Brake cleaner is acceptable to remove remaining CVT fluid.
CAUTION: Avoid any debris from dropping into the torque converter housing or the
CVT case.

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3. Apply sealant to the CVT case side of the torque converter housing to CVT case mating
surface.


Sealant bead diameter: 2.0 mm

Sealant:
 Loctite 5460 (See the Parts Information section of this bulletin)
 Color: Pink
IMPORTANT:
 Confirm that the mating surfaces are clean before applying sealant.
 Make sure that the starting point and the ending point of the sealant is
between two bolt holes. Overlap both ends of the bead by 3 – 5 mm.
 If the Guide Pins were removed to clean the case surfaces, reinstall them
now.
CAUTION: Be careful not to contact or contaminate the sealant. If the sealant has
been disturbed or contaminated in any way before case assembly, remove the
sealant completely and re-apply.

Figure 2S

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4. Install the torque converter housing onto the CVT case with nineteen (19) new bolts and
torque to the pattern shown in Figure 3S.
NOTE: If the torque converter housing does not fully seat, the CVT may not be in
DRIVE.


Use new bolts.
NOTE: See Reference # 9 in the KIT PARTS REFERENCE TABLE.
 Bolt torque: 27.1 N•m (2.8 kg-m, 20 ft-lbs.)
IMPORTANT: Tighten the bolts in specific order shown below.

1

5
17

3

11
18

10
16
9

15

12
8
7

19
6

14

13

4
2
Figure 3S

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Install the Valve Body and Oil Pan

1. Rotate the CVT assembly so that the
torque converter housing side is facing
down.

Terminal
assembly

O-ring
2. Make sure that the terminal assembly is
attached to the bracket of the new valve
body (Figure 1T).

Bracket

NOTE:



Apply CVT Fluid to the O-ring of
the terminal connector.
See Reference # 1 in the KIT
PARTS REFERENCE.

Figure 1T

3. Install the new valve body assembly to
the CVT case.


Insert the terminal assembly through
the hole of the CVT case, and then
push the new valve body horizontally
with even pressure to seat the valve
body completely.
NOTE: A clicking sound may be
heard as the new valve body is
seated to the CVT case.
Figure 2T

4. First tighten all eleven (11) original valve
body bolts finger tight by hand, and then
tighten to the specified bolt torque below.

Valve body bolts

CAUTION: These bolts are easily
stripped. Use care to not over-torque.


87 mm (3.4 inches) long bolt.
11 pieces
 Bolt torque:
7.9 N•m, (0.80 kg-m, 70 in-lbs.)

CAUTION: Manual valve may slide down
and interfere with CVT case.
Manual valve

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Figure 3T

NTB17-034e

5. Install the original manual plate to the
manual shaft with the original spring
washer and lock nut.


Use a crescent wrench on the
transmission range switch side of the
manual rod to keep the shaft from
rotating while torqueing.



Nut torque:
21.7 N•m (2.2 kg-m, 16 ft-lbs.)

Nut and washer

Manual plate

Figure 4T

6. Confirm that the new O-ring is on the new
oil strainer.


Apply CVT Fluid to the O-ring before
installation.

NOTE:



The new oil strainer comes with a
new O-ring.
See Reference # 3 in the KIT
PARTS REFERENCE TABLE.

O-ring

Figure 5T

7. Install the new strainer to the valve body
with the three (3) original bolts.


3 bolts

12 mm (0.5 inches) long bolt.
3 pieces
 Bolt torque:
7.9 N•m (0.80 kg-m, 70 in-lbs.)
Strainer

Figure 6T

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8. Install the original oil pan with a new oil
pan gasket using the original bolts.
 Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lbs.)
NOTE: See Reference # 2 in the KIT
PARTS REFERENCE TABLE.

Figure 7T

83/129