

The thrust bearing must sit flush with primary pulley surface (Figure 19E).



Re-use the thrust bearing which was removed from the planetary carrier plate.

Primary pulley

Thrust bearing

Primary pulley
bearing surface

Figure 19E

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20. Coat the primary pulley bearing, secondary pulley gear teeth and the secondary bearing
with CVT fluid prior to installation (Figure 20E).
IMPORTANT: Do NOT apply sealant to the case at this time. The sub-assembly will be
sealed later in this procedure.
The following Figures are for reference only and may or may not have the sealant in
place, or have the old sealant removed. Clean the surfaces and apply sealant when
and where instructed.

Coat these
surfaces with
CVT fluid

Figure 20E
21. Position the new sub-assembly over the CVT case and then lower it just far enough to
allow the Guide Pins to be inserted into their appropriate sub-assembly holes (the Guide
Pins are different lengths).
IMPORTANT: Do NOT allow the output gear to contact the lubrication tubes when the
side cover is positioned over the guide pins.
NOTE: Guide pin locations are shown in Figure 9E on page 36.

Output
Gear
Lubrication
Tube

Lubrication
Tube
Figure 21E
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IMPORTANT:
Before continuing, it is recommended that you review and understand the instructions on
pages 42 to 47.


Confirm dowel pins are clean – this will ease installation.



The sub-assembly will lower into the CVT case without applying extra vertical
force.



IF THE SUB-ASSEMBLY DOES NOT LOWER COMPLETELY,
INTERFERENCE IS PRESENT.

! PHYSICAL

Key Technique: Raise to remove weight on interference, adjust as necessary, and
then lower again.
Use the “gap size” between the sub-assembly and the CVT case to determine the cause of
interference. At any given gap, only 1 item will be the cause of interference

50 mm - Page 43
40 mm - Page 44

CASE GAP = ?

18 mm - Page 45
5 mm
Page 46

Figure 22E

Case gap

Figure 23E

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22. Carefully lower the Lifting Fixture to install the sub-assembly into the CVT case as
follows:


While visually looking down into the bore (Figure 25E) to confirm that the output gear
is clearing the CVT case bearing bore,
a. Level the sub-assembly by placing hands on top to guide it into the CVT case.
b. Lower the sub-assembly until a gap of 40 mm (1.6 inch) is present to the CVT

case (Figure 28E on page 44) and then proceed to step 23.
 If the sub-assembly will not lower any farther than 50 mm (2 inches) the
output gear has not cleared the bearing bore (Figure 25E).
Sub-assembly will not lower past 50 mm (2 inches)?
 Interference is present between the output gear and bearing bore and are
highlighted with yellow in Figure 24E and 25E.

Sub-assembly

50 mm
(2 inches) gap

Output gear

Bearing bore

Output gear

Figure 24E

Bearing bore
CVT case
Figure 25E
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23. Install the parking rod into the parking pawl of the CVT sub-assembly as follows:
IMPORTANT: Perform step 23 while the sub-assembly has a 40 mm gap (1.6 inch) to
the CVT case (Figure 28E).
a. Rotate the shift select lever clockwise on the side of the CVT to adjust the park rod

to the highest position.
b. Use a magnet, or similar tool, to align the park rod in the CVT case (

in Figure
in Figure 26E) in the side cover.

27E) with the opening in the parking pawl (
NOTE:

 If the parking rod is not located correctly it may keep the case from lowering.
 If the parking rod is not located correctly, the shift select lever will not rotate
through all detents (P-R-N-D-L) once the sub-assembly is completely installed.

Side cover
Parking pawl

Parking rod
CVT case
Figure 26E

Figure 27E

Sub-assembly

40 mm (1.6
inch) gap

CVT case

Figure 28E

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24. Continue to slowly lower the sub-assembly into the CVT case.


If the primary and the secondary pulley bearings do not align properly with their
bores (Figure 29E) or are at an angle, a gap of 18 mm (0.7 inch) may be present.



Possible areas of interference are highlighted with orange and tan in Figure 29E.
 As needed, level the sub-assembly as it is lowered into the CVT case to help the
primary and the secondary pulley bearings align in their bores.
 MINOR LEVELING ADJUSTMENTS with limited weight on the sub-assembly will
help the installation. Vertical force is not needed.
 Once the sub-assembly is LEVEL the primary and the secondary pulley bearings
will smoothly align while lowering.

Sub-assembly will not lower past 18 mm (0.7 inch)?


If this occurs Do NOT force sub-assembly into case.
a. Raise the sub-assembly slightly.
b. Level the sub-assembly (visually check the gap between case and sub-assembly
side cover and confirm that it is even all around).
c. Gently lower the sub-assembly.
d. Gently shake the sub-assembly horizontally, lower, raise and repeat as needed
to help align.
e. Lower to clear dowel pins to 6 mm (0.25 inch).

Sub-assembly
18 mm (0.7
inch) gap

Primary
pulley bearing
Secondary
pulley bearing

Bearing bore

Bearing bore
Figure 29E

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IMPORTANT: In the following steps the case halves must sit flush against each other
without a gap before installing the bolts. The bolts CANNOT be used to draw the cases
together. DO NOT APPLY VERTICAL FORCE.
25. Once the dowel pins are cleared, ease the sub-assembly down onto the CVT case until
the case halves are flush.


Confirm the dowel pins are clean and aligned and are not catching on the subassembly case cover.
WARNING: Be careful not to get fingers caught between the CVT case and subassembly when seating.

Sub-assembly will not lower past 5 mm (0.2 inch)?
If the sub-assembly will not lower past 5 mm (0.2 inch), the primary pulley splines are
interfering with the planetary carrier splines.


If this occurs Do NOT force sub-assembly into case.
a. Raise the sub-assembly slightly to separate physical spline interference.
b. Slightly rotate the primary pulley back and forth slowly, through the bottom of the
CVT, and then lower the sub-assembly.
c. Repeat as needed.

Sub-assembly

Primary pulley

5 mm (0.2
inch) gap

Rotate pulley in
green highlighted
area only

CVT case

Touch side of primary
pulley to align splines

Primary
pulley splines
Planetary
carrier splines
Figure 30E

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Do not place fingers
below primary pulley

NTB17-039e

Shift select lever
26. Rotate the select lever to “N” range.


This helps keep the sub-assembly
level.

Figure 31E

Lifting Fixture
27. Remove the Lifting Fixture from the side
cover.


Loosen the wing nuts



Unthread the tool from the pulley
brackets.

Figure 32E

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Remove Side Cover and Install Lubrication Caps
IMPORTANT: In the following steps, use only slide hammer and hands to separate side
cover.
In the following steps, if the side cover does not easily lift off by hand
it is still
seated on the pulley bearings and must first be completely separated.

Do NOT use tool J-52275 at this time.

1. Install two Pulley Bracket Guide Pins
(J-52272).


The bracket guide pins will be used as
a height marker of the pulleys to
ensure they remain seated in the case
as the side cover is removed.

Pulley Bracket Guide
Pins (J-52272)

2. Use slide hammer (J-25721-A) with Jhook case separator (J-51923) and
evenly separate the side cover from the
belt and pulley assembly.


Alternate between the three hooking
locations on the side cover until the
side cover separates from pulleys
(see page 37 Figure 11E).
 As the side cover is raised up, the
exposed height of the pulley guide
pins will shorten. This is an
indicator that the pulleys are
remaining seated in the CVT case.

Slide hammer (J-25721-A) with
J-hook case separator (J-51923)
Figure 1F
Raise evenly; lift by hand.

 Make sure the side cover is
completely separated from the
pulley bearings.
 Once side cover is separated from
pulley bearings, it will rock freely
and can be easily lifted by hand.
IMPORTANT: Use only slide hammer
and hands to separate side cover from
pulleys.

Figure 2F

3. Lift off the side cover by hand.
NOTE: The side cover weighs 9 lbs.
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4. Install two (2) new lubrication caps (see Parts Information) shown in Figure 3F onto the
tubes of the CVT case shown in Figure 4F as follows:
a. Insert the lubrication caps through the slots in each chain guide.
b. Face the larger side of the “wedge shaped index guide” away from the pulleys.
c. Gently push each lubrication cap down into the square cut seat of the CVT case
tubes.
NOTE: Slightly rotating the lubrication caps will help in aligning them into the square
cut seats.
IMPORTANT: Confirm that caps are installed in the correct orientation.

Lubrication
cap

Lubrication
cap

Lubrication
cap

Wedge
shaped index

Chain guide

Figure 3F
This Figure is shown with the pulleys and chain removed to
illustrate how the lubrication caps attach to the CVT case tubes
and is for reference only.
Lubrication
cap

Wedge
shaped index

Square cut
seat
CVT case
tube
Figure 4F
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Guide pins

5. Confirm two Pulley Bracket Guide Pins
(J-52272) are in place.


One guide pin to each pulley bracket.



Can be installed into any of the three
bolt holes.
Figure 5F

6. Rotate each bracket to align with holes in
the case as shown in Figure 6F.

Align these
holes

Pulley Bracket
Guide Pins go here
Figure 6F
O-ring

7. Install a new O-ring.


Apply CVT fluid to the O-ring before
installation.



Press down completely into machined
groove.

NOTE: Do not re-use the old O-ring.

Figure 7F

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Shim
8. Confirm that the shim and the lathe cut
seal, on the underside of the side cover,
stay in place.


The shim is located in the secondary
pulley bearing bore.



Lathe cut seal is located in the center
of the same bearing bore.

NOTE: Apply petroleum jelly or
equivalent as needed to keep the shim
and lathe cut seal in place while lowering
the side cover to the CVT.

Install Side Cover

Lathe cut seal
Figure 8F

Side Cover Alignment
Aid (#J-52275)

1. Install the Side Cover Alignment Aid (#J52275), with two (2) bolts hand tight.
NOTE: The Alignment Aid will assist with
level installation and help keep integrity
of sealant until the case halves are flush
against one another.

2. Lift side cover with suitable lifting tool and
confirm that the underside case mating
surface is clean.
Figure 9F

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3. Apply one continuous 2.0 mm diameter bead of sealant along the center of the CVT
case side mating surface (Figure 10F).
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 10F

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Manual lever
4. Rotate the manual lever clockwise to the
“P” range to set the parking rod at the
highest position.

Figure 11F

5. Install the CVT Assembly Guide Pins
(#J-51959).

IN THE FOLLOWING STEPS IF THE
SIDECOVER DOES NOT LOWER
COMPLETELY,
PHYSICAL
INTERFERENCE IS PRESENT.
NOTE: Before installing side cover read
steps 6-9.

Figure 12F

6. Install the side cover to the CVT case.
a. Route each of the 4 guide pins from
under the side cover through their
respective bolt holes.

Not shown with sealant
and is for reference only.

b. Lower the side cover until the parking
rod can be aligned with parking pawl
and then proceed to step 7 on the
next page.


See Figure 14F on page 54.

IMPORTANT:


Keep the side cover as level as
possible during installation.



To assist with proper pulley
positioning, confirm the CVT is on a
flat surface.



Do not use excessive vertical force to install.

Figure 13F

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7. Install the parking rod into the parking pawl of the CVT side cover as follows:
IMPORTANT: Perform step 7 while the side cover has a 38 mm gap (1.5 inch) to the
CVT case (Figure 16F).
a. Rotate the shift select lever clockwise on the side of the CVT to adjust the park rod

to the highest position.
b. Use a magnet, or similar tool, to align the park rod in the CVT case (

in Figure
in Figure 14F) in the side cover.

15F) with the opening in the parking pawl (
NOTE:

 If the parking rod is not located correctly it may keep the side cover from
lowering.
 If the parking rod is not located correctly, the shift select lever will not rotate
through all detents (P-R-N-D-L) once the side cover is completely installed.

Side cover

Not shown with sealant
and is for reference only.