Punch

Detent
plate
Manual
shaft

Use the appropriate
size punch to prevent damage to
the roll pin or detent plate.

Figure 165

HINT: See Reference # 12 in the KIT
PARTS REFERENCE TABLE.

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Install Powertrain Parts

135. 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 inches) long bolt.
 Bolt torque:
6.8 N•m (0.70 kg-m, 60 in-lbs.)

Figure 166

136. Install the original shim for the input
shaft in the counter bearing bore
(Figure 167).


If the counter bearing is a type “A”
(roller bearing) continue to step
137 on page 81.



If the counter bearing is a type “B”
or “C” (ball bearing) skip to step
139 on page 81.

Input shaft
shim

Figure 167

NOTE: Type ”C” counter bearing
shown in Figure 168. Type “B” is
similar.

Counter
bearing

Figure 168

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137. For type “A” bearings, install the outer race of the roller bearing to the counter bearing
bore of the CVT case, if it has not been done already.
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 170

Figure 169

138. If the input shaft assembly is, for any reason, separated into individual components,
see steps 97f- 95h on pages 60 - 62 to reassemble those parts, otherwise continue to
step 139.

139. Install the input shaft assembly to the
CVT case


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.

Input shaft

Do not draw the input
shaft assembly down to the case with
the mounting bolts or damage to the
CVT may occur.

Figure 171

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140. 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.)



1.2 inch
long bolts

0.6 inch
long bolts

30 mm (1.2 inches) long bolt
4 pieces.
 Bolt torque:
27.1 N•m (2.8 kg-m, 20 ft-lbs.)

Chain cover
Figure 172

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

Sleeve

142. Install the sleeve to the reverse brake
tube.


Use a new sleeve (non-reusable).



Apply CVT Fluid to the sleeve
before installation.

HINT: See Reference # 20 in the KIT
PARTS REFERENCE TABLE.
Figure 173

143. Install the reverse brake tube to the
CVT case.


Reverse
brake
tube

16 mm (0.6 inches) long bolt.
 Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lbs.)
2 Bolts

Insert the tube to the
CVT case vertically and evenly to
avoid damage to the sleeve.

Figure 174

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144. Connect the parking rod to the detent
plate as shown in Figure 175.
Parking
rod

Detent
plate

Figure 175

145. Rotate the detent plate until the detent is in the “D” position (Figure 176 and
Figure 177).


The detent roller position shall be on the second left concave of the detent plate.

Parking
rod
P
R
N
D

Figure 176

Figure 177

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146. 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 178 and Figure 179).
147. Expand the snap ring with a suitable tool, and then push down on the driven sprocket
until it bottoms out.
148. Release the snap ring and then pull up on the driven sprocket until the snap ring locks
into its groove.
HINT: A click sound can be heard when the snap ring locks in place.
Driven sprocket
Sprockets
and chain

Snap ring

Figure 178

Figure 179

149. Install the original thrust bearing onto
the drive sprocket.
HINT: Install the thrust bearing with the
exposed bearings facing up.

Drive sprocket

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.

O-ring

153. Install the lip seal to the CVT case.



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:

Lip seal

a. Clean any debris out of the
machined grooves that the two
Ring Seals will be installed into.

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 KIT
PARTS REFERENCE TABLE.
Reduction
gear assembly

Machine
cut seals

Figure 185

Figure 184
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NTB20-036a

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

86/148

Figure 188

NTB20-036a

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.

n. Remove the Second Groove Seal
Tool.


Ring
Seal

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 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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NTB20-036a

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 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