Thrust bearing
Figure 180

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

Input shaft

151. 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

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

Figure 181
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152. Install the CVT case O-ring (oval
O-ring) to the CVT case.


Use a new oval O-ring (nonreusable).



Apply CVT Fluid to the O-ring
before installation.

HINT: See Reference # 11 in the KIT
PARTS REFERENCE TABLE.
153. Install the lip seal to the CVT case.



O-ring
Figure 182

Use a new lip seal.
Apply CVT Fluid to the lip seal
before installation.

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

Use petroleum jelly to help hold the
seals in place.
155. Replace the two machine cut seals
(Ring Seals) of the reduction gear
assembly, shown in Figure 184 and
Figure 185 as follows:
a. Clean any debris out of the
machined grooves that the two
Ring Seals will be installed into.

Lip seal
Figure 183

These seals are VERY delicate. Handle with care to avoid damage.
HINT: See Reference # 21 in the KIT PARTS REFERENCE TABLE.


Machine cut seals can be ordered in packs of 50. See the part number in the
KIT PARTS REFERENCE TABLE.

Reduction
gear assembly

Machine
cut seals

Figure 185

Figure 184
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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 186

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.

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

Ring
seal

First
groove

i. Remove the First Groove Seal Tool.
Figure 187
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 188

NTB20-035a

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.

n. Remove the Second Groove Seal
Tool.


Ring
Seal

Second
groove

m. Gently push the ring seal onto the
second groove.

Figure 189

Confirm that both of the Ring Seals are not protruding in any direction.
HINT: 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.

In the following step use extreme care when installing the final drive and
reduction gear assembly to avoid damage to components/seals.


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 the
machine cut seals are in place and centered in their grooves.

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

Thrust bearing

Reduction gear
assembly bore
Figure 190

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157. 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.

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

Final drive
Figure 191

Install the Torque Converter Housing
159. Place the original thrust washer on the
torque converter housing.


Thrust washer

Torque converter
housing

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

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

Figure 192

160. Remove any remaining CVT fluid on the sealing surfaces of the torque converter
housing and the CVT case.
HINT: Brake cleaner is acceptable to remove remaining CVT fluid.
To prevent possible CVT damage, prevent any debris from entering into
the torque converter housing or the CVT case.

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161. 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 on page 140 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.
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 to prevent possible leaks.

Overlap
3-5 mm

Figure 193

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162. Install the torque converter housing onto the CVT case with nineteen (19) new bolts
and torque to the following pattern shown in Figure 194.
NOTE: If the torque converter housing does not fully seat, the CVT may not be in
Drive.


Use new bolts.

HINT: 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.
HINT: The bolts not visible in Figure 194 are indicated with a dotted green circle.

1
5
3

17

18

11

10
16
9

15

12
8
7

19
6

14

13

4
2
Figure 194

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Install the Control Valve and Oil Pan

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

Terminal
assembly

164. Make sure that the terminal assembly
is attached to the bracket of the new
control valve (Figure 195).

O-ring

HINT:



Bracket

Apply CVT Fluid to the O-ring of
the terminal connector.
See Reference # 1 in the KIT
PARTS REFERENCE.
Figure 195

165. Install the new control valve assembly
into 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.

HINT: A clicking sound may be heard
as the new control valve is seated to
the CVT case.
Figure 196
166. First tighten all eleven (11) original
control valve bolts circled in yellow
finger tight by hand, and then tighten
to the specified bolt torque below.

Control valve bolts

These bolts are easily
stripped. Use care to not over-torque
as this can damage the CVT.


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

Manual valve

Figure 197

HINT: The manual valve may slide
down and interfere with CVT case.
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167. Install the original manual plate to the
manual shaft with the original spring
washer and lock nut.


Use an adjustable wrench on the
transmission range switch side of
the manual rod to keep the shaft
from rotating while tightening.



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

Manual plate

Figure 198
168. Confirm that the new O-ring is on the
new oil strainer.


Apply CVT Fluid to the O-ring
before installation.

HINT:



O-ring

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

Figure 199

169. 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 200

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170. Remove the magnets from the CVT oil pan.
HINT: The CVT oil pan may come with two (2) or three (3) magnets.

171. Clean the magnets.

172. Clean the CVT oil pan.

173. Reinstall the magnets to the CVT oil pan in their original positions.

174. Install the CVT 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.)
HINT: See Reference # 2 in the KIT
PARTS REFERENCE TABLE.

Figure 201

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Seal the Sub-assembly Cover

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

Side cover

176. Remove the two temporary side
cover bolts.

Figure 202

177. Remove the two pulley bearing
retainer bolts.


Pulley bearing
retainer bolts

These bolts will be reused later in
this procedure.

Figure 203
178. Remove the side cover.


Use a slide hammer (J-25721-A) if
needed.



There are three slide hammer tool
locations on the side cover.

HINT: Figure 204 shown with side
cover removed.

Figure 204

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179. Install the original lubrication tube into
the CVT case.


Place the fluid jet nozzle under the
CVT belt and then insert the
lubrication tube into the CVT case.

To avoid damage to the
CVT belt, take care not to contact the
CVT belt with any tools during tube
installation.

Lubrication
tube

Figure 205

Lubrication
tube bolt

180. Install the original lubrication tube bolt.


16 mm (0.6 inches) long bolt.
 Bolt torque:
6.8 N•m (0.70 kg-m, 60 in-lb).

Lubrication
tube
Figure 206

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181. Apply sealant to the side cover sealing surface of the CVT case.


Sealant bead diameter: 2.0 mm

Sealant:
 Loctite 5460 (See the PARTS INFORMATION on page 140 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.
Be careful not to contact or contaminate the sealant. If the sealant has
been disturbed or contaminated in any way before side cover assembly is installed,
remove the sealant completely and reapply to prevent possible leaks.

Overlap
3 mm to 5 mm

Figure 207

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Assembly Guide
Pins, Pulley Bracket
(Guide Pin J-52272)

182. Screw in Guide Pin (J-52272) to either
one of the two female bolt threads of
the pulley bearing retainer.


Case
bolt hole

Place the guide pin next to the
case bolt hole as shown in Figure