next to the dowel pins.

Figure 78

Dowel Pin

Guide Pin
Figure 79

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61.

Raise the Lifting Fixture so that the CVT assembly weight is mostly supported by the
Lifting Fixture and just slightly raised off of the work surface.

62.

Loosen the side cover with a slide hammer at the three points (tool location marks)
shown in Figure 80.


Rotate between the three (3) locations on the side cover until the CVT case
separates from the sub-assembly; this can take more than one rotation to loosen
sealant.
CAUTION: DO NOT use a pry-bar, chisel, etc. to separate the side cover from
the CVT case.

NOTE: Apply rust penetrant to the two dowel pins as needed.
Tool location marks
Figure 80 shows a similar side
cover and is for reference only

Dowel
pin

Dowel
pin

63.

Figure 80

Raise the Lifting Fixture to remove the
“side cover with pulleys and belt subassembly” (sub-assembly) from the
CVT case (Figure 81).
CAUTION: Make sure the primary
speed sensor is removed from the
sub-assembly.


The speed sensor will be reused.



DO NOT discard the speed sensor.



This sub-assembly will not be
reused.

Figure 81
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64.

Remove the lifting fixture from the sub-assembly.


65.

Re-install all six (6) original bolts into the old sub-assembly.

Thoroughly clean the mating surfaces of the CVT case (Figure 82) that the subassembly was just separated from (a plastic scraper can be used).


Confirm that the dowel pins have remained in the CVT case. If not, remove them
from the sub-assembly and reattach them back to the CVT case.

NOTE: The Guide Pins can be temporarily removed for cleaning purposes.
CAUTION:
o DO NOT use sanding discs, metal blades, or similar abrasive tools.
o Use brake cleaner or equivalent solvent and lint-free towels only.
o Make sure brake cleaner or solvents used are compatible with local regulations.
o Prevent debris from entering in the CVT.
o Make sure rust and debris have been cleaned off of dowel pins and receiving holes.
66.

Replace the O-ring on the CVT case side with a new one from the PARTS KITS
REFERENCE TABLE; discard the original O-ring (Figure 83).


Coat the O-ring with CVT fluid before installing.

Mating surfaces

O-ring
Figure 82

67.

Figure 83

Remove the thrust bearing from the
planetary carrier plate (Figure 84).


This thrust bearing will be
reused. DO NOT discard.
CAUTION: If not found on the
planetary carrier plate, the thrust
bearing may still be attached to the
primary pulley.

Thrust bearing
Figure 84
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68.

Rotate the shift select lever counter clockwise to the “L” range position
(Figure 85), so that the parking pawl is at its lowest position (Figure 86).

Parking
pawl

Shift select lever

Figure 85
69.

Figure 86

Attach the Lifting Fixture to the new sub-assembly, and then raise the sub-assembly
out of the shipping box.


First remove the six (6) bolts from the new sub-assembly and then remove their Orings before installing the Lifting Fixture.
 These bolts will be reused.
 These O-rings will not be reused.

CAUTION: To prevent cross threading, always tighten the bolts by hand.


Refer to step 58 through step 60 for lifting fixture attachment information.

Lifting Fixture

Sub-assembly
Figure 87

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70.

Apply one continuous 2.0 mm diameter bead of sealant along the center of the CVT
case side mating surface (Figure 88).
Sealant:
 Loctite 5460 (see PARTS INFORMATION on page 91)
 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.
CAUTION: Be careful not to contact or contaminate the sealant. If the sealant has
been disturbed or contaminated in any way before case assembly, thoroughly clean
the mating surfaces of the CVT case and re-start from step 70.

Figure 88

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71.

Install the original thrust bearing on the primary pulley of the new sub-assembly
(Figure 89).
IMPORTANT: The thrust bearing surface must lay flush with the primary pulley. Any
additional height will affect the total end play that is measured later in this procedure.
CAUTION: The thrust bearing has two sides. Reference Figure 90 for bearing
orientation.


Apply a small amount of petroleum jelly or equivalent to the original thrust bearing
to hold it in place on the primary pulley.

Primary pulley

Thrust bearing

Thrust bearing; must sit
flush with primary pulley
surface
Figure 90

Figure 89

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72.

Coat the primary pulley bearing, secondary pulley gear teeth and the secondary
bearing with CVT fluid prior to installation (Figure 91 and Figure 92).
CAUTION: Do NOT drip any CVT fluid onto the sealant.

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

Output gear

Figure 91
73.

Figure 92

While lowering the sub-assembly, route the Guide Pins into the appropriate CVT bolt
holes one at a time (the Guide Pins are different lengths for easy assembly).
IMPORTANT: Do NOT allow the output gear to contact the lubrication tube when the
side cover is positioned over the guide pins (Figure 94 and Figure 95).

Lubrication
tube

Figure 93

Figure 94

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F.

IMPORTANT:
Before continuing, it is recommended that you review and understand the instructions on
pages 47 to 51.
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 “visual gap size” below (Figure 95 and Figure 96), between the sub-assembly and
the CVT case, to determine the cause of interference.

44 mm - Page 46
38 mm - Page 47

CASE GAP = ?

19 mm - Page 48
6 mm Page 49

Figure 95

Case gap

Figure 96
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74.

Carefully, lower the Lifting Fixture to install the sub-assembly into the CVT case until a
38 mm (1.5 inch) gap is present between the sub-assembly and CVT case. See
Figure 101 on page 49.


Look in to the bearing bore to confirm the output gear is centered (Figure 98).



Place hands on top of the sub-assembly to keep it level and guide it into the
CVT case.


If the sub-assembly will not lower farther than 44 mm (1.75 inches) the
output gear did not clear the bearing bore (Figure 97).

Sub-assembly will not lower past 44 mm (1.75 inches)?


Interference is present between the output gear and bearing bore.

Sub-assembly

44 mm (1.75
inch) gap

CVT case

Output gear

Bearing bore

Output gear

Figure 97

Bearing bore
CVT case
Figure 98

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CAUTION: In the following steps 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-start from step 70 on page 44.
75.

Align the parking rod with the parking pawl as follows:
IMPORTANT: Perform step 75 while there is a 38 mm (1.5 inch) gap between the the
sub-assembly and CVT case (Figure 101).
a. Rotate the shift select lever clockwise on the side of the CVT to adjust the parking
rod to the highest position.
b. Use a magnet, or similar tool, to align the parking rod in the CVT case (
in
Figure 100) with the opening in the parking pawl (
in Figure 99) in the side
cover.
NOTE: If the parking rod is not located correctly it will keep the case from
lowering.

The following Figures are for reference only.
Side cover

Parking pawl
Parking rod
Pocket
magnet
Figure 99

CVT case
Figure 100

Sub-assembly

38 mm (1.5
inch) gap

CVT case
Figure 101
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76.

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 102) or are at an angle, a gap of 19 mm (0.75 inches) may be
present.
 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 19 mm (0.75 inches)?


If this occurs Do NOT force the sub-assembly into the 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 engage the dowel pins and a 6 mm (0.25 inch) gap is between the subassembly and CVT case.

Sub-assembly

Primary
pulley bearing

19 mm (0.75
inch) gap

Secondary
pulley bearing
Bearing bore

CVT Case

Bearing bore
Figure 102

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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.
77.

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 6 mm (0.25 inches)?
If the sub-assembly will not lower past 6 mm (0.25 inches), the primary pulley splines are
not aligned.


If this occurs Do NOT force sub-assembly into case.
a. Raise the sub-assembly slightly so the weight is not completely on the primary
pulley splines.
b. Slightly rotate the primary pulley through the bottom of the CVT and then lower
the sub-assembly.
c. Repeat as needed.

Sub-assembly
Primary pulley
6 mm (0.25
inch) gap

Belt
element
CVT
case

Primary pulley
splines

Touch side of primary
pulley to align splines
Planetary
carrier splines

Do not place fingers
below primary pulley

Figure 103
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Rotate the shift select lever

78.

Confirm the parking rod operation as
follows:
a. Rotate the shift select lever counter

clockwise and confirm that all
detents for each of the P-R-N-D-L
are felt.
b. Rotate the lever clockwise to return

the rod back to the P position.
c. Are all of the detents felt?

 YES: Proceed to step 79.

Figure 104

 NO: If the lever does not rotate
or if all detents are not felt:
1) Raise the sub-assembly and remove all sealant.
2) Restart from step 70 on page 44.

79. Remove the guide pins.

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80.

Install the new side cover bolts (Figure 105).


Torque the first eight (8) bolts marked as
in the sequence numbered in
Figure 105 below, and then torque the rest of the bolts in a clockwise direction.
 Bolt torque: 45 N•m (4.6 kg-m, 33 ft-lb) 19 pieces.

8

4
2
6

Torque un-numbered bolts
in clockwise direction

3
1
5
7
Figure 105
81.

Remove the Lifting Fixture.

82.

Install six (6) new O-rings, from the Parts Kits Reference Table on page 95, to the
six (6) new pulley bearing retainer bolts that were removed from the new subassembly on page 43, step 69.

83.

Install the six (6) new pulley bearing
retainer bolts finger tight.


Do not use tools to install.

Figure 106

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