cap

Wedge
shaped index

Chain guide

Figure 105
Figure 106 shows the pulleys and chain removed to illustrate
how the lubrication caps attach to the CVT case tubes and is for
reference only.
Lubrication
cap

Wedge
shaped index

Square cut
seat
CVT case
tube
Figure 106
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Guide pins
79.

Confirm two Pulley Bracket Guide Pins
(J-52272) are in place.


One guide pin to each pulley
bracket.



The guide pins can be installed
into any of the three bolt holes.

Figure 107

80.

Rotate each bracket to align with holes
in the case as shown in Figure 108.

Align these
holes

Pulley Bracket
Guide Pins go here
Figure 108
O-ring

81.

Install a new O-ring.


Apply CVT fluid to the O-ring
before installation.



Press down completely into the
machined groove.

HINT: Do not re-use the old O-ring.

Figure 109

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82.

Shim

Confirm that the shim and the lathe cut
seal, on the underside of the side
cover, stay in place.


The shim is located in the
secondary pulley bearing bore.



The lathe cut seal is located in the
center of the same bearing bore.

HINT: Apply petroleum jelly or
equivalent as needed to keep the shim
and lathe cut seal in place while
lowering the side cover to the CVT.

Lathe cut seal
Figure 110

Install Side Cover
Side Cover Alignment
Aid (#J-52275)
83.

Install the Side Cover Alignment Aid
(#J-52275), with two (2) bolts hand
tight.
HINT: The Alignment Aid will assist
with level installation and help keep
integrity of sealant until the case
halves are flush against one another.

84.

Lift side cover with suitable lifting tool
and confirm that the underside case
mating surface is clean.
Figure 111

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85.

Apply one continuous 2.0 mm diameter bead of sealant along the center of the CVT
case side mating surface (Figure 112).
Sealant:
o Loctite 5460 (See the PARTS INFORMATION section of this bulletin.)
o Color: Pink
IMPORTANT:
o Confirm that the mating surfaces are clean before applying sealant.
o 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.
o If the Guide Pins were removed to clean the case surfaces, reinstall them now.
HINT: 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.

Figure 112

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Manual lever
86.

Rotate the manual lever clockwise to
the “P” range to set the parking rod at
the highest position.

Figure 113
87.

Install the CVT Assembly Guide Pins
(#J-51959).

IN THE FOLLOWING STEPS IF THE
SIDE COVER DOES NOT LOWER
COMPLETELY,
PHYSICAL
INTERFERENCE IS PRESENT.
HINT: Before installing side cover read
steps 88-91.
88.

Install the side cover to the CVT case.
a. Route each of the 4 guide pins
from under the side cover through
their respective bolt holes.

Figure 114

Not shown with sealant
and is for reference only.

b. Lower the side cover until the
parking rod can be aligned with
parking pawl and then proceed to
step 89 on the next page.
o See Figure 116 on page 54.
IMPORTANT:
o Keep the side cover as level as
possible during installation.
o To assist with proper pulley
positioning, confirm the CVT is
on a flat surface.

Figure 115

o Do not use excessive vertical force to install.

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89.

Install the parking rod into the parking pawl of the CVT side cover as follows:
IMPORTANT: Perform step 89 while the side cover has a 38 mm gap (1.5 inch) to
the CVT case (Figure 118).
a. Rotate the shift select lever clockwise on the side of the CVT to adjust the park

rod to the highest position.
b. Use a magnet, or similar tool, to align the park rod in the CVT case (

in
in Figure 116) in the side

Figure 117) with the opening in the parking pawl (
cover.
HINT:

o If the parking rod is not located correctly it may keep the side cover from
lowering.
o If the parking rod is not located correctly, the shift select lever will not rotate
through all detents (P-R-N-D-L) once the side cover is completely installed.

Side cover

Not shown with sealant
and is for reference only.

Parking pawl

Parking rod
CVT case
Figure 117

Figure 116

Not shown with sealant
and is for reference only.

Side cover

38 mm (1.5
inch) gap

CVT case

Figure 118

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Apply pressure to
these locations

90.

Using your hand, press down on the
side cover over each of the pulley
bearings to level and seat the side
cover.
IMPORTANT: The side cover will not
be fully seated at this step.

Figure 119 Side Cover
Alignment Aid
(# J-52275)

91.

Rotate the manual lever to the “N”
position.

92.

Remove the Side Cover Alignment Aid
(# J-52275) shown in Figure 119.

HINT: Figure 120 shown with Side
Cover Alignment Aid removed.
Figure 120

93.

Continue to lower the side cover until it is flush with the CVT case.


Use a plastic hammer or rubber mallet, if the side cover is caught, and gently tap
evenly around the top of the side cover to help seat.

IMPORTANT:
Side cover must be completely seated.
Bolts cannot be used to draw case halves together.
Do NOT use metal hammers or mallets.
If it is necessary to unseat the side cover assembly, use a slide hammer and
then restart from step 83 on page 51.
o Do NOT pry with a screw driver.
o
o
o
o

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94.

Remove the two (2) CVT Assembly Guide Pins (# J-51959).


95.

Leave the Pulley Bracket Guide Pins in place.

Install the sub-assembly side cover with nineteen (19) new side cover bolts to the
CVT case (Figure 121).
IMPORTANT: Do not reuse the original side cover bolts.


Torque the first eight (8) bolts marked as
in the sequence numbered in
Figure 121 below, and then torque the rest of the bolts in a clockwise manner.
o Bolt torque: 45 N•m (4.6 kg-m, 33 ft-lb) 19 pieces.

Some bolts are hidden

4

8

2
6

Torque un-numbered
bolts in clockwise pattern

3
1

5
7
Figure 121

96.

Install six (6) new O-rings from PARTS INFORMATION to the six (6) new pulley
bearing retainer bolts that were removed from the new sub-assembly on page 39,
step 64.

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97.

Install the new pulley bearing retainer
bolts to secure the pulleys and side
cover.
a. Install four (4) bolts first, hand tight.
b. Remove two (2) guide pins from
the pulley bracket.
c. Install the last two (2) bolts with Orings, hand tight.
Figure 122

98.

Confirm the parking rod operates
correctly as follows:
a. Rotate the shift select lever
counterclockwise and confirm that
all detents for each of the
P-R-N-D-L are felt.

Shift select lever

b. Rotate the lever clockwise to return
the rod back to the P position.
c. Are all of the detents felt?
o YES: Proceed to step 99.
o NO: If the lever does not rotate
or if all detents are not felt:

Figure 123

1) Remove the sub-assembly side cover and then remove sealant.
2) Restart from step 83 on page 51.

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99.

Confirm the rotational smoothness of
the primary pulley as follows:
a. With a clean hand, access the
primary pulley from the bottom of
the CVT to rotate.
b. Rotate the primary pulley by hand
and confirm that the characteristic
is the same as previously checked
at step 51 (page 34), prior to
removing the original subassembly.

Figure 124

c. Is the rotational characteristic “the
same” (OK) or “worse than before
the sub-assembly was replaced”
(NG)?
o OK: The rotational characteristic is the same or better; proceed to step 100.
o NG:
1) Remove the 19 case bolts and 6 pulley bracket bolts. Refer to page 35
steps 52 and 53.
2) Install the 2 Pulley Bracket Guide Pins (J-52272). Refer to page 48
step 75.
3) Remove the side cover.
4) Remove the 2 lubricating caps.
5) Remove the silicone from the sealing surfaces.
6) Reinstall the side cover and then remove the Pulley Bracket Guide Pins.
7) Restart sub-assembly installation from Step 54 on Page 36.
8) Recheck rotational characteristics.

100. Torque all six (6) bolts.


Bolt torque:
28 N•m (2.8 kg-m, 20 ft-lbs).

Figure 125

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101. Install the CVT case side axle seal
(Figure 126).


Use Seal Installer J-52283 and
Driver Handle J-8092.



Apply a light coat of CVT fluid to
the seal lip surfaces.

J-8092
CVT
case

J-52283

Figure 126

102. Place the CVT on the work bench with
the side cover facing down on the
bench.

Bolts
103. Remove the converter housing which
was temporarily installed with three
bolts.

Converter housing
Figure 127

104. Unbolt the three (3) bolts holding the
dummy cover and then remove the
dummy cover.

Bolts

Dummy cover
Figure 128

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Depth Gauge “Zero” Procedure

IMPORTANT: The Depth Gauge MUST be set to “zero” before performing measurements
in the following SERVICE PROCEDURE.

Measurement tools:


Gauge Block (straight bar)



Depth Gauge (Digital Vernier scale) with a datum level (accuracy: 0.01 mm)

Depth Gauge
Bottom out

“ZERO” switch
ON/OFF switch

Inch/mm switch

Lay flat
Datum level
Gauge Block
Figure 129

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Depth Gauge Calibration
To calibrate the Digital Depth Gauge J-50272:
a. Turn the Depth Gauge ON and set it to “mm” measurement.
b. Place the Depth Gauge’s datum level flush on top of the Gauge Block.
c. Carefully slide the depth marker down until it bottoms out on the Gauge Block.
d. With the depth marker bottomed out, press the “ZERO” switch.
o The Depth Gauge’s display should now read 0.00 mm.
HINT:


Push (extend) the depth marker to the gauge block to correctly zero.



Do not use the gauge block to push (retract) the depth marker up to the datum point.

Depth marker

Datum level flush
with Gauge Block

Figure 130

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Pages 62-66 are for Type 1 Thrust Bearing ONLY. Proceed to page 67 if working with
Type 2 Thrust Bearing (with bearing race).

Type 1 CVT: Clutch Total Endplay Adjustment – Thrust Bearing Selection
IMPORTANT: The clutch total endplay (Figure 131) must always be adjusted when a new
sub-assembly is installed.


The Type 1 CVT uses the thrust bearing thickness between the clutch drum of
clutch assembly and the dummy cover to adjust the total endplay.

Thrust Bearing Selection
There are eight (8) thicknesses of thrust bearings available for total endplay adjustment.


For additional information, see video # 547: “CVT Belt and Pulley Replacement”
and fast forward to minute marker 13:10. This video is located under the TECH
TRAINING GARAGE VIDEOS tab in Virtual Academy.

Dummy
cover

CVT case

Total
endplay

Clutch
drum

Thrust
bearing