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.
O-ring

NOTE: See Reference # 7 in the KIT
PARTS REFERENCE TABLE.
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.


Use a new lip seal (non-reusable).



Apply CVT Fluid to the lip seal before
installation.

O-ring
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.
Ring
Seal

First
groove

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

Figure 19R

i. Remove the First Groove Seal Tool.
Second Groove Seal
Tool (#J-52595-2)
j. Slide the Second Groove Seal Tool
(#J-52595-2) over the reduction gear
shaft.


Confirm that it is completely
seated.

Reduction
gear assembly

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Figure 20R

NTB17-034L

Seal Driver (#J-52595-3)
k. Place one (1) Ring Seal onto the
Second Groove Seal Tool.

l.

Slide the Seal Driver (#J-52595-3) over
the Second Groove Seal Tool.

m. Gently push the Ring Seal onto the
second groove.

Ring
Seal

Second
groove

n. Remove the Second Groove Seal
Tool.


Figure 21R

Confirm that both of the Ring Seals are not protruding in any direction.
NOTE: If the reduction gear shaft is not going to be immediately installed, the
Split Ring Seal Cover (#J-52595-4) can be slid over both Ring Seals to prevent
damage.

CAUTION: In the following step use extreme care when installing the final drive and
reduction gear assembly.


The machine cut seals are VERY delicate and will damage easily if forced.



The reduction gear assembly should seat without any additional force.



If the reduction gear assembly does not seat, remove it and confirm that machine cut
seals are in place and centered in their grooves.

23. Confirm that the thrust bearing is in place
in the bottom of the reduction gear
assembly bore.

Thrust bearing

Reduction gear
assembly bore
Figure 22R

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24. Install the final drive and reduction gear
assembly together into the CVT case.


If the reduction gear assembly does
not seat, remove it and confirm that
machine cut seals are in place and
centered in their grooves.

25. Rotate the final drive by hand to confirm
that it rotates freely.

Final drive
Figure 23R

Install the Torque Converter Housing
Torque converter
housing

1. Place the original thrust washer on the
torque converter housing.


Thrust washer

Apply petroleum jelly to the mating
surface side of the washer to hold the
washer on the converter housing.

NOTE: Both sides of the thrust washer
are the same, orientation is not critical.

Figure 1S

2. Remove any remaining CVT fluid on the sealing surfaces of the torque converter
housing and the CVT case.
NOTE: Brake cleaner is acceptable to remove remaining CVT fluid.
CAUTION: Avoid any debris from dropping into the torque converter housing or the
CVT case.

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3. Apply sealant to the CVT case side of the torque converter housing to CVT case mating
surface.


Sealant bead diameter: 2.0 mm

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.

Overlap
3-5 mm

Figure 2S

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4. Install the torque converter housing onto the CVT case with nineteen (19) new bolts and
torque to the pattern shown in Figure 3S.
NOTE: If the torque converter housing does not fully seat, the CVT may not be in
DRIVE.


Use new bolts.
NOTE: See Reference # 9 in the KIT PARTS REFERENCE TABLE.
 Bolt torque: 27.1 N•m (2.8 kg-m, 20 ft-lbs.)
IMPORTANT: Tighten the bolts in specific order shown below.

1

5
17

3

11
18

10
16
9

15

12
8
7

19
6

14

13

4
2
Figure 3S

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Install the Control Valve and Oil Pan

1. Rotate the CVT assembly so that the
torque converter housing side is facing
down.

Terminal
assembly

O-ring

2. Make sure that the terminal assembly is
attached to the bracket of the new control
valve (Figure 1T).
NOTE:



Bracket

Apply CVT Fluid to the O-ring of
the terminal connector.
See Reference # 1 in the KIT
PARTS REFERENCE.

Figure 1T

3. Install the new control valve assembly to
the CVT case.


Insert the terminal assembly through
the hole of the CVT case, and then
push the new control valve
horizontally with even pressure to
seat the control valve completely.
NOTE: A clicking sound may be
heard as the new control valve is
seated to the CVT case.

Figure 2T

4. First tighten all eleven (11) original
control valve bolts finger tight by hand,
and then tighten to the specified bolt
torque below.

Control valve bolts

CAUTION: These bolts are easily
stripped. Use care to not over-torque.


87 mm (3.4 inches) long bolt.
11 pieces
 Bolt torque:
7.9 N•m, (0.80 kg-m, 70 in-lbs.)

CAUTION: Manual valve may slide down
and interfere with CVT case.

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Manual valve

Figure 3T

NTB17-034L

5. Install the original manual plate to the
manual shaft with the original spring
washer and lock nut.


Use a crescent wrench on the
transmission range switch side of the
manual rod to keep the shaft from
rotating while torqueing.



Nut torque:
21.7 N•m (2.2 kg-m, 16 ft-lbs.)
Nut and washer

Manual plate

Figure 4T

6. Confirm that the new O-ring is on the new
oil strainer.


Apply CVT Fluid to the O-ring before
installation.

NOTE:



The new oil strainer comes with a
new O-ring.
See Reference # 3 in the KIT
PARTS REFERENCE TABLE.

O-ring

Figure 5T

7. Install the new oil strainer to the control
valve with the three (3) original bolts.


12 mm (0.5 inches) long bolt.
3 pieces

3 bolts

 Bolt torque:
7.9 N•m (0.80 kg-m, 70 in-lbs.)

Oil strainer
Figure 6T

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8. Install the original oil pan with a new oil
pan gasket using the original bolts.
 Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lbs.)
NOTE: See Reference # 2 in the KIT
PARTS REFERENCE TABLE.

Figure 7T

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Seal the Sub-assembly Cover

1. Confirm the torque converter housing
side is facing down.

Side cover