Figure 181

Figure 182

148.…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 183
149.

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

150.

Install the new O-ring onto the input
shaft.



Input shaft

Use a new O-ring (non-reusable).
Apply CVT Fluid to the O-ring
before installation.

HINT: See Reference # 7 in the KIT
PARTS REFERENCE TABLE on
page 150.
87/153

O-ring
Figure 184
NTB22-021

151.

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 on
page 150.
152.

O-ring

Install the O-ring to the CVT case.



Use a new O-ring.
Apply CVT Fluid to the O-ring
before installation.

Figure 185

HINT: See Reference # 10 in the KIT
PARTS REFERENCE TABLE on
page 150.
153.

Confirm that both seals are seated
in their grooves.


Use petroleum jelly to help hold
the seals in place.
154. Replace the two machine cut seals
(Ring Seals) of the reduction gear
assembly, shown in Figure 187 and
Figure 188 as follows:
a. Clean any debris out of the
machined grooves that the two
Ring Seals will be installed into.

O-ring

Figure 186

These seals are VERY delicate. Handle with care to avoid damage.
HINT: See Reference # 21 in the KIT PARTS REFERENCE TABLE on page 150.
 Machine cut seals can be ordered in packs of 50. See the part number in KIT
PARTS REFERENCE TABLE on page 150.
Reduction
gear assembly

Machine
cut seals

Figure 187

Figure 188
88/153

NTB22-021

First Groove Seal
Tool (#J-52595-1)
b. Pre-lube both machined grooves
with CVT fluid.
c. Slide the First Groove Seal Tool
(#J-52595-1) over the reduction
gear shaft.

d. Confirm that it is completely
seated.
Figure 189

Reduction
gear assembly

e. Pre-lube both Ring Seals with
CVT fluid.

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

g. Slide the Seal Driver (#J-525953) over the First Groove Seal
Tool.

i. Remove the First Groove Seal
Tool.

Ring
seal

First
groove

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

Figure 190
Second Groove Seal
Tool (#J-52595-2)

j. Slide the Second Groove Seal
Tool (#J-52595-2) over the
reduction gear shaft.
o Confirm that it is completely
seated

Reduction
gear assembly

89/153

Figure 191

NTB22-021

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

l. Slide the Seal Driver (#J-525953) over the Second Groove Seal
Tool.
Ring
Seal

Second
groove

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

Figure 192

n. Remove the Second Groove
Seal Tool.

o 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.

155.



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.

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

Thrust bearing

Reduction gear
assembly bore
Figure 193
90/153

NTB22-021

156.

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

157.

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

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

Final drive
Figure 194

Install the Torque Converter Housing
158.

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

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.

Thrust washer

Figure 195

159.

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.

91/153

NTB22-021

160.

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 145 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 196

92/153

NTB22-021

161.

Install the torque converter housing onto the CVT case with nineteen (19) new bolts
and torque to the following pattern shown in Figure 197.
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 on page 150.
o 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 197 are indicated with a dotted green circle.

Torque converter
housing bolts (19)

2

19

4

6

7

8

18
9
17
10
16

11
15
5

13

12

1
14

3

Figure 197

93/153

NTB22-021

Install the Control Valve and Oil Pan
162.

163.

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

Terminal
assembly

O-ring

Make sure that the terminal assembly
is attached to the bracket of the new
control valve (Figure 198).
HINT:



164.

Apply CVT Fluid to the O-ring of
the terminal connector.
See Reference # 1 in the KIT
PARTS REFERENCE on page
150.

Bracket
Figure 198

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 199
165.

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

Control valve
bolts (11)

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

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

Manual valve

Figure 200

HINT: The manual valve may slide down and interfere with the CVT case.
94/153

NTB22-021

166.

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

Manual plate

Figure 201
167.

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 on
page 150.
Figure 202

168.

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

12 mm (0.5 inch) long bolt,
3 pieces

Oil strainer bolts (3)

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

Oil strainer
Figure 203

95/153

NTB22-021

169.

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

170.

Clean the magnets.

171.

Clean the CVT oil pan.

172.

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

173.

Install the CVT oil pan with a new oil
pan gasket using the original bolts.




Tighten the CVT oil pan bolts
in the sequence shown
(Figure 204).

11

5
1

3
12

10
9

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

13

Oil pan
bolts (15)

14
8