CVT case

New sub-assembly
Bolts

Figure 156

Figure 157

127. 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 158.



Weight: 29 kg (64 lbs.)

Sub-assembly
side cover

76/147

Figure 158

NTB20-035C

Install the Oil Pump and the Manual Shaft

128. Install the oil pump gasket to the CVT
case.


Use a new gasket (non-reusable).



Apply CVT fluid before installation.

CVT case

HINT: See Reference # 14 in the KIT
PARTS REFERENCE TABLE.
Oil pump
gasket

Figure 159
129. 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.

CVT case

Manual shaft

Oil pump
Do not remove the manual shaft
completely from the CVT case. If the
retaining pin slot contacts the seal,
damage may occur.
130. Install a new oil pump to the CVT case.


Reuse the three original Allen®
bolts for the oil pump.



35 mm (1.4 inch) long bolt.

Figure 160

o Bolt torque:
20.3 N•m (2.1 kg-m, 15 ft-lb)
HINT: See Reference # 13 in the KIT
PARTS REFERENCE TABLE.
131. Install the snap ring that came out of
the original oil pump to the new oil
pump.
Snap ring
Figure 161

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NTB20-035C

Manual shaft

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

Oil pump
Figure 162
Retaining
pin

133. Install the original retaining pin as
shown in Figure 163.


Align the manual shaft groove
(Figure 164) to allow the retaining
pin (Figure 163) to go through
completely.
Manual shaft

Figure 163

Groove for the retaining pin (straight pin)

Figure 164
Slide
direction

Hole for the roll pin

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NTB20-035C

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.

134. 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).



Punch size: Diameter 3 mm,
Length 20 mm or longer.

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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NTB20-035C

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 inch) long bolt.
o 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

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

Counter
bearing

Figure 168

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NTB20-035C

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 - 97h 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.

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

81/147

Input shaft

Figure 171

NTB20-035C

140. Install the original chain cover and the
six (6) original bolts and then tighten.


16 mm (0.6 inch) long bolt
2 pieces.
o Bolt torque:
5.6 N•m (0.60 kg-m, 50 in-lb)



1.2 inch
long bolts

0.6 inch
long bolts

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

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 inch) long bolt.
o 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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NTB20-035C

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 177

Figure 176

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NTB20-035C

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.

Thrust bearing

Drive sprocket

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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NTB20-035C

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:
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.
o 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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NTB20-035C

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.
o Confirm that it is completely
seated

Reduction
gear assembly

86/147

Figure 188

NTB20-035C

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.
Ring
Seal

Second
groove