 Use brake cleaner or equivalent solvent and lint-free towels only.
 Make sure brake spray or solvents used are compatible with local regulations
 Avoid debris entering into the inside of the CVT.
 Make sure rust and debris have been cleaned off of the dowel pins and
receiving holes.
61.

Remove the O-ring from the CVT case (Figure 84).


This O-ring will not be reused.

Mating surfaces

O-ring

Figure 84

Figure 83

62.

Remove the thrust bearing from the
planetary carrier plate (Figure 85).


The 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 85

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Shift select lever
63.

Rotate the shift select lever counter
clockwise to the “L” range position
(Figure 86), so that the parking rod is
at its lowest position (Figure 87).

Figure 86

Parking rod

Figure 87

64.

65.

Remove the six (6) bolts from the new
sub-assembly and then remove their
O-rings.


These bolts will be reused.



These O-rings will not be reused.

Lifting Fixture

Attach Lifting Fixture to the new subassembly, and then raise subassembly out of shipping box.
CAUTION: Do not cross thread side
cover holes when installing the Lifting
Fixture. Always start bolts by hand.

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Sub-assembly
Figure 88

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66.

Install the original thrust bearing onto the primary pulley of the new sub-assembly
(Figure 89).
CAUTION: The thrust bearing has two different sides. Reference Figure 89 for
correct bearing orientation.


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



The thrust bearing must sit flush with primary pulley surface (Figure 89).



Reuse the thrust bearing which was removed from the planetary carrier plate.

Primary pulley

Thrust bearing

Primary pulley
bearing surface
Figure 89

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67.

Coat the primary pulley bearing, secondary pulley gear teeth and the secondary
bearing with CVT fluid prior to installation (Figure 90).
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 90
68.

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 79 on page 36.

Output
Gear
Lubrication
Tube

Lubrication
Tube
Figure 91

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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 the sub-assembly to remove weight from the 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 92

Case gap

Figure 93

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69.

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

While visually looking down into the bore (Figure 95) 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 98 on page 44) and then proceed to step 70.
 If the sub-assembly will not lower any farther than 50 mm (2 inches) the
output gear has not cleared the bearing bore (Figure 95).
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 94 and Figure 95.

Sub-assembly

50 mm
(2 inches) gap

Output gear

Bearing bore

Output gear

Figure 94

Bearing bore
CVT case
Figure 95

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70.

Install the parking rod into the parking pawl of the CVT sub-assembly as follows:
IMPORTANT: Perform step 70 while the sub-assembly has a 40 mm gap (1.6 inch)
to the CVT case (Figure 98).
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 parking rod in the CVT case (

Figure 97) with the opening in the parking pawl (

in
in Figure 96) in the side cover.

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 97

Figure 96

Sub-assembly

40 mm (1.6
inch) gap

CVT case

Figure 98

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71.

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 99) 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 99.
 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 subassembly 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 6 mm (0.25 inch) to clear the dowel pins.

Sub-assembly

Primary
pulley bearing
Secondary
pulley bearing

18 mm (0.7
inch) gap

Bearing bore

Bearing bore
Figure 99

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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.
72.

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 the primary pulley and the
planetary carrier splines to remove 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

Do not place fingers
below primary pulley

Figure 100
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Shift select lever
73.

Rotate the select lever to “N” range.


This helps keep the sub-assembly
level.

Figure 101

Lifting Fixture
74.

Remove the Lifting Fixture from the
side cover.


Loosen the wing nuts.



Unthread the tool from the pulley
brackets.

Figure 102

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Remove Side Cover and Install Lubrication Caps
IMPORTANT: In the following steps, use only a slide hammer and hands to separate the
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.

75.

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

76.

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)

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 the pulleys (see
page 37 Figure 81).
 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 103
Raise evenly; lift by hand.

 Make sure the side cover is
completely separated from the
pulley bearings.
 Once the side cover is
separated from pulley bearings,
it will rock freely and can be
easily lifted by hand.
IMPORTANT: Use only a slide hammer
and hands to separate the side cover
from the pulleys.
77.

Figure 104

Lift off the side cover by hand.
NOTE: The side cover weighs 9 lbs.
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78.

Install two (2) new lubrication caps (see Parts Information) shown in Figure 105 onto
the tubes of the CVT case shown in Figure 106 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 the caps are installed in the correct orientation.

Lubrication
cap

Lubrication
cap

Lubrication
cap

Wedge
shaped index

Chain guide

Figure 105
Figure 106 shows 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 106
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Guide pins
79.

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

One guide pin to each pulley
bracket.



The guide pins can be installed
into any of the three bolt holes.

Figure 107

80.

Rotate each bracket to align with holes
in the case as shown in Figure 108.

Align these
holes

Pulley Bracket
Guide Pins go here
Figure 108
O-ring

81.

Install a new O-ring.


Apply CVT fluid to the O-ring
before installation.



Press down completely into the
machined groove.

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

Figure 109
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82.

Shim

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.



The 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.

Lathe cut seal
Figure 110