1. Install new ground post at top of transmission case.
Tighten ground post until snug.
NOTE
A new transmission case comes with the shifter shaft sleeve and seal, centering screw, countershaft needle bearing and main drive gear bearing and seal installed.
2. Thoroughly wipe all engine oil from pockets in crankcase flange.
3. Install new engine-to-transmission gasket engaging two index pins in holes of transmission flange.
4. Verify that transmission dowels are seated. Place transmission case into position behind crankcase. Mate engine and transmission flanges.
5. Install and tighten fasteners.
a. Install shorter fasteners at the top, longer fasteners at the bottom. Hand tighten fasteners in a crosswise pattern.
b. See Figure 6-58. Tighten bolts in the sequence shown to 15 ft-lbs (20.3 Nm) in the same crosswise pattern.
c. Final tighten bolts to 34-39 ft-lbs (46.1-52.9 Nm).
6. Install oil pan. See 3.31 OIL PAN.
7. Install rear fork. See 2.22 REAR FORK, Installation.
8. Install shift arm on shift shaft. Align marks made during disassembly.
9. Install transmission and bearing housing assembly. See 6.8 TRANSMISSION ASSEMBLY, Installation.
10. Secure battery ground cable to ground post at top of transmission case. Tighten to 66-114 in-lbs (7.5-12.9 Nm).
11. Adjust drive belt tension. See 1.14 DRIVE BELT AND SPROCKETS.
12. Install primary chaincase. See 5.5 PRIMARY CHAINCASE HOUSING.
13. Install drive components. See 5.4 DRIVE COMPONENTS.
NOTE
Always install a new gasket between primary chaincase cover and chaincase. Failure to replace this gasket may cause primary chaincase leaks.
14. Install primary chaincase cover. See 5.3 PRIMARY CHAINCASE COVER.
15. Install neutral switch. Tighten to 120-180 in-lbs (13.6-20.3 Nm).
16. Install VSS with screw. Tighten to 100-120 in-lbs (11.3-13.6 Nm).
17. Mate VSS, O2 sensors, starter solenoid and neutral switch connectors to main harness.
18. Install starter. See 7.8 STARTER, Installation.
19. Install exhaust system. See 4.18 EXHAUST SYSTEM.
20. Install drain plug. Tighten to 14-21 ft-lbs (19.0-28.5 Nm).
Fill transmission. See 1.11 TRANSMISSION LUBRICANT.
Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)
21.Fill primary chaincase. See 1.10 PRIMARY CHAINCASE LUBRICANT, Changing Primary Chaincase Lubricant.
22. Fill engine oil. See 1.6 ENGINE OIL AND FILTER, Changing Oil and Oil Filter.
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
23. Connect battery cables.
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