To avoid damage to the CVT:
o Only use the weight of the
CVT case when installing it to
the sub-assembly.

New subassembly

Primary pulley
sub-assembly

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

b. Align the primary pulley front
bearing bore of the CVT case to
the primary pulley front bearing of
the sub-assembly.
HINT: Figure 154 is shown
looking down into the CVT case
while it is being lowered.

Figure 153

CVT case

Primary
pulley front
bearing bore
Figure 154

c. Align one of two dowel pin holes
found on the CVT case to the
sub-assembly.

CVT case

Dowel pin
New sub-assembly
Figure 155

76/153

NTB22-021

d. Align the second dowel pin of the
sub-assembly with the hole on the
opposite side of the CVT case and
seat the CVT case.

Dowel pin
Figure 156
e. If the CVT case will not seat on the
sub-assembly:
i.

Access the counter driven gear
through the top of the CVT
case,
and

ii.

Rotate the counter driven gear
on the primary pulley back and
forth.
HINT: This will allow the splines
of the secondary pulley and the
planetary carrier plate to align.
(Figure 158).

Counte
Counter
r driven
driven
gear

Figure 157

Secondary
pulley splines
Figure 158
77/153

NTB22-021

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.
i.

If this occurs, first lift the CVT case up slightly and then lower.

ii.

Repeat until the CVT case and sub-assembly sit flush with each other.

CVT case

No gap

New sub-assembly
Figure 159
g. Rotate the counter driven gear back and forth by hand to confirm its rotation is
smooth.

78/153

NTB22-021

125. Temporarily install two (2) original bolts hand tight to hold the sub-assembly cover to
the CVT case.
CVT case

New sub-assembly

Bolts (2)

Figure 161

Figure 160

126. 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 162.



Weight: 29 kg (64 lbs.)

Sub-assembly
side cover

79/153

Figure 162

NTB22-021

Install the Oil Pump and the Manual Shaft

127. Install the two (2) oil pump gaskets to
the CVT case.


Use new gaskets (non-reusable).



Apply CVT fluid before
installation.

HINT: See Reference # 14 in the KIT
PARTS REFERENCE TABLE on
page 150.

CVT case

Oil pump
gasket

Oil pump
gasket
Figure 163

128. 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 90
on page 48.
Do not remove the manual shaft
completely from the CVT case. If the
retaining pin slot contacts the seal,
damage may occur.
129. Install a new oil pump to the CVT
case.




CVT case

Manual shaft

Oil pump

Oil pump hex bit
screw fasteners (3)

Reuse the three (3) original hex
bit screw fasteners for the oil
pump.

Figure 164

35 mm (1.4 inch) long bolt.
o Bolt torque:
20.3 N•m (2.1 kg-m,
15 ft-lbs.)

HINT: See Reference # 13 in the KIT
PARTS REFERENCE TABLE on
page 150.
Snap ring

130. Install the snap ring that came out
of the original oil pump to the new
oil pump.

Figure 165

80/153

NTB22-021

Manual shaft

131. Slide the manual shaft back to the
original position.

Figure 166

132. Install the original retaining pin, as
shown in Figure 167.


Retaining
pin

Align the manual shaft groove
(Figure 168) to allow the retaining
pin (Figure 167) to go through
completely.

Manual shaft
Figure 167

Groove for the retaining pin (straight pin)

Figure 168
Slide
direction

Hole for the roll pin

81/153

NTB22-021

To prevent CVT operational issues, use care when assembling the manual shaft and detent
plate.


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.

133. Install the new roll pin through the
detent plate and manual shaft.




Roll pin

The roll pin must be inserted
through the detent plate so that
both ends are the same length.

Punch

Use a new roll pin (non-reusable).

Use the appropriate size punch to
prevent damage to the roll pin or
detent plate.
HINT: See Reference # 12 in the KIT
PARTS REFERENCE TABLE on
page 150.

82/153

Detent
plate

Manual
shaft
Figure 169

NTB22-021

Install Powertrain Parts

134.

Install the original manual shaft
detent spring to the CVT case.

Detent spring
Tab

IMPORTANT: Locate the tab of the
detent spring to the hole of the CVT
case.


16 mm (0.6 inch) long bolt.
o Bolt torque:
6.8 N•m (0.70 kg-m, 60 inlbs.)

Figure 170

135.

Install the original shim for the input
shaft in the counter bearing bore
(Figure 171).

Input shaft
shim

Figure 171

83/153

NTB22-021

136. 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.

Input shaft
assembly
Outer race

Counter
bearing bore

Outer race
Figure 173

Figure 172

137.

If the input shaft assembly is, for any reason, separated into individual components,
see steps 96f - 96h on pages 64 - 65 to reassemble those parts, otherwise continue
to step 138.

138.

Install the input shaft assembly to
the CVT case as follows:

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.

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

84/153

Figure 174

NTB22-021

139.

Install the original chain cover and
the six (6) original bolts, and then
tighten (Figure 175).


1.2
inch
long
bolts

16 mm (0.6 inch) long bolt
2 pieces, circled in green.

0.6 inch
long bolts

o Bolt torque: 5.6 N•m
(0.60 kg-m, 50 in-lbs.)


30 mm (1.2 inch) long bolt
4 pieces, circled in yellow.
o Bolt torque: 27.1 N•m
(2.8 kg-m, 20 ft-lbs.)

Chain cover
Figure 175

140.

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

141.

Install the sleeve and the O-ring to
the reverse brake tube.

O-ring



Use a new sleeve and a new
O-ring (non-reusable).



Apply CVT Fluid to the sleeve and
the O-ring before installation.

HINT: See Reference # 20 in the KIT
PARTS REFERENCE TABLE on
page 150.
142.

Sleeve

Figure 176

Install the reverse brake tube to
the CVT case.


Reverse
brake
tube

16 mm (0.6 inch) long bolts.
o Bolt torque: 5.6 N•m
(0.60 kg-m, 50 in-lbs.)

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

Reverse
brake tube
bolts (2)
Figure 177

85/153

NTB22-021

143.

Install the parking rod as follows:
a. Rotate the detent plate until the
detent is in the “L” position, as
shown in Figure 178.

Parking
rod

o The detent roller position
should be on the leftmost
concave position of the
detent plate.
b. Rotate the parking rod vertically
to align the tab on the parking rod
with the slot on the detent plate,
and then install it into the detent
plate.

Detent spring
in “L” position

Align tab
with slot in
detent plate

Figure 178

Parking rod
bolts (2)

c. Install the two (2) parking rod
bolts (Figure 179).
o Bolt torque: 28.8 N•m
(2.9 kg-m, 21 ft-lbs.)

Figure 179

144.

Detent spring
in “D” position

Rotate the detent plate until the
detent is in the “D” position, as
shown in Figure 180.


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

Figure 180

86/153

NTB22-021

145.…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 181 and Figure 182).
146....Expand the snap ring with a suitable tool, and then push down on the driven
.sprocket until it bottoms out.
147.…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