→



Add value for “B1” from data sheet

→ + B1 ___________
------------------------------------



Total calculated depth

→

=

___________

= E ___________

E = This will be used to select a snap ring from Table A on page 68.

EXAMPLE:
If D = 41.39 mm
Constant
= 41.30 mm (subtracted)
And B1 = 1.56 mm (added)
____________________
E = 1.65 mm

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12. Select the appropriate Part Number from Table A shown below, based on the calculated
result of “E” in step 11 on the previous page.
EXAMPLE: If E = 1.65, and is between or equal to 1.64 to 1.67, choose new snap ring
Part Number “31506 3JX9C”.
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
1.65
1.69
1.73
1.77 Example only. Do
1.79 not use in your
calculations.

Table A
E (MM)
1.55 to 1.59
1.60 to 1.63
1.64 to 1.67
1.68 to 1.71
1.72 to 1.75
1.76 to 1.76

PART NUMBER
31506 3JX9A
31506 3JX9B
31506 3JX9C
31506 3JX9D
31506 3JX9E
31506 3JX8A

SNAP RING REFERENCE (MM)
1.61
1.65
1.69
1.73
1.77
1.79

13. Open the plastic bag (with snap rings) that was removed from the shipping box in step
4, and then choose the correct Part Number selected from Table A.
NOTE: There are six individually packed snap rings in the plastic bag. See Reference #
5 in the KIT PARTS REFERENCE TABLE.
14. Measure the new snap ring and confirm its thickness is equal to the Snap Ring
Reference in Table A.
15. Install the selected snap ring to the secondary pulley front bearing of the new subassembly.
NOTE: Discard unused snap rings.

Selected snap ring
Figure 10N

Figure 11N
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Install Sub-assembly to CVT Case

CVT case sealing
surface
1. Make sure the CVT case sealing surface
of the side cover is thoroughly cleaned.

2. Make sure the dowel pins are cleaned
and any rust has been removed.

Figure 1P
Torque converter
housing
3. Flip the CVT case over on the work
bench with the torque converter housing
side facing up.
CAUTION: Make sure the work bench
surface is thoroughly cleaned before
flipping the CVT case.

4. Remove the two (2) temporary bolts and
then remove the torque converter
housing from the CVT case.


Discard these bolts.
Figure 2P

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5. Install the CVT case onto the new subassembly as follows:

CVT case

NOTE: Sealant will be applied between
these components at a later step.
a. Slowly lower the CVT case onto the
sub-assembly.
IMPORTANT:


Only use the weight of the
CVT case when installing it to
the sub-assembly.



Do NOT use any other
external force to seat the CVT
case to the sub-assembly.

New
sub-assembly

Figure 3P
Primary pulley
sub-assembly

b. Align the “primary pulley front
bearing bore” of the CVT case to the
primary pulley front bearing of the
sub-assembly.

CVT case

NOTE: Figure 4P is shown looking
down into the CVT case while it is
being lowered.

Primary pulley
front bearing bore
Figure 4P

c. Align one of two dowel pin holes
found on the CVT case to the subassembly.

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

73/146

Figure 12P

NTB17-034L

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.

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 44.
CAUTION: Do not remove the manual
shaft completely from the CVT case. If
the retaining pin slot contacts the seal,
damage may occur.

Oil pump
gasket
Figure 1Q
CVT case

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 42.

Input shaft
shim

Figure 2R

3. If the counter bearing is a type “B” or “C”
(ball bearing) skip to step 6 on page 78.
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 58-59 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.
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.
