CVT case

Dowel pin
New sub-assembly
Figure 5P

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d. Align the second dowel pin of the subassembly with the hole on the
opposite side of the CVT case and
seat CVT case.

Dowel pin
Figure 6P
e. If the CVT case will not seat on the
sub-assembly:
1) Access the counter driven gear
through the top of the CVT case,
and
2) Rotate the counter driven gear on
the primary pulley back and forth.
NOTE: This will allow the splines
of the secondary pulley and the
planetary carrier plate to align.
See Figure 8P.

Counter
driven gear

Figure 7P
Counter
driven gear

Secondary
pulley splines

Figure 8P
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f. Confirm that the mating surface of the CVT case is seated to the sub-assembly
completely.


If the CVT case does not sit completely flush with the sub-assembly, DO NOT
apply any vertical force to seat it.
1) If this occurs, first lift the CVT case up slightly and then lower.
2) Repeat until the CVT case and sub-assembly sit flush with each other.

CVT case

No gap

New sub-assembly
Figure 9P

g. Rotate the counter driven gear back and forth by hand to confirm that rotation is
smooth.

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6. Temporarily install two (2) original bolts hand tight to hold the sub-assembly to the CVT
case.

CVT case

New sub-assembly

Bolts

Figure 10P

Figure 11P

7. Lift the sub-assembly / CVT case away
from the cradle and set aside; discard the
cradle.


Leave the sub-assembly side cover
facing down as shown in Figure 12P.



Weight: 29 kg (64 lbs.)

Sub-assembly
side cover

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Figure 12P

NTB17-034j

Install the Oil Pump and the Manual Shaft

CVT case

1. Install the oil pump gasket to the CVT
case.


Use a new gasket (non-reusable).



Apply CVT Fluid before installation.

NOTE: See Reference # 14 in the KIT
PARTS REFERENCE TABLE.
Oil pump
gasket

2. Remove the hand tight transmission
range switch bolts and then slide the
manual shaft out only far enough to
install the oil pump. See Figure 22H on
page 43.

Figure 1Q
CVT case

CAUTION: Do not remove the manual
shaft completely from the CVT case. If
the retaining pin slot contacts the seal,
damage may occur.

Manual shaft

Oil pump

3. Install a new oil pump to the CVT case.


Reuse the three original Allen® bolts
for the oil pump.



35 mm (1.4 inches) long bolt.
 Bolt torque:
20.3 N•m (2.1 kg-m, 15 ft-lbs.)

Figure 2Q

NOTE: See Reference # 13 in the KIT
PARTS REFERENCE TABLE.

4. Install the snap ring that came out of the
original oil pump to the new oil pump.
Snap ring
Figure 3Q

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Manual shaft
5. Slide the manual shaft back to the
original position.

Oil pump
Figure 4Q

Retaining
pin

6. Install the original retaining pin as shown
in Figure 5Q.


Align the manual shaft groove (Figure
6Q) to allow the retaining pin (Figure
5Q) to go through completely.
Manual
shaft

Figure 5Q

Groove for the retaining pin (straight pin)

Slide
direction

Hole for the roll pin
Figure 6Q

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IMPORTANT:
In the following step:
 Do not drive the roll pin flush with the detent plate.
 If the roll pin is driven flush, it will be overextended on the opposite side and the
manual shaft/detent plate assembly will not rotate.
 The roll pin MUST be the same length on both sides of the detent plate after it is
installed through the detent plate and manual shaft.

7. Install the new roll pin through the detent
plate and manual shaft.


The roll pin must be inserted through
the detent plate so that both ends are
the same length.



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

1. Install the original manual shaft detent
spring to the CVT case.

Tab

Detent spring

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 41.

Input shaft
shim

Figure 2R

3. If the counter bearing is a type “B” or “C”
(ball bearing) skip to step 6 on page 77.
NOTE: Type ”B” counter bearing shown
in Figure 3R. Type “C” is similar.

Counter
bearing

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 57-58 to reassemble those parts.

6. Install the input shaft assembly to the
CVT case

Input shaft



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

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Figure 6R

NTB17-034j

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.)

8. Rotate the input shaft by hand to confirm
that the shaft rotates freely.

Figure 7R

Chain cover

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

Thrust bearing
Figure 13R

17. Rotate the input shaft by hand to confirm
that the chain, pump and shaft rotate
freely.

Input shaft

18. Install the new O-ring onto the 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.
20. Install the lip seal to the CVT case.
O-ring



Use a new lip seal (non-reusable).



Apply CVT Fluid to the lip seal before
installation.

Figure 15R

NOTE: See Reference # 10 in the KIT
PARTS REFERENCE TABLE.
21. Confirm that both seals are seated in
their grooves.


Use petroleum jelly to help hold the
seals in place.

22. Replace the two machine cut seals (Ring
Seals) of the reduction gear assembly,
shown in Figure 17R as follows:
a. Clean any debris out of the machined
grooves that the two Ring Seals will
be installed into.

Lip seal
Figure 16R

CAUTION: These seals are VERY delicate. Handle with care.
NOTE: See Reference # 21 in the KIT PARTS REFERENCE TABLE.
 Machine cut seals can be ordered in packs of 50. See part number in kit parts
reference table.
Reduction
gear assembly

Machine cut
seals

Figure 17R
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First Groove Seal
Tool (#J-52595-1)
b. Pre-lube both machined grooves with
CVT fluid.
c. Slide the First Groove Seal Tool (#J52595-1) over the reduction gear
shaft.
d. Confirm that it is completely seated.
Reduction
gear assembly

e. Pre-lube both Ring Seals with CVT
fluid.

Figure 18R

Seal Driver (#J-52595-3)
f. Place one (1) Ring Seal onto the First
Groove Seal Tool.
g. Slide the Seal Driver (#J-52595-3)
over the First Groove Seal Tool.

i.

Ring
Seal

First
groove

h. Gently push the Ring Seal onto the
first groove.

Figure 19R

Remove the First Groove Seal Tool.
Second Groove Seal
Tool (#J-52595-2)

j.