2. Disconnect the following wires:
- a. Reverse light switch wires.
- b. Black/white wire of starter solenoid.
3. On fuel injected models, the air cleaner assembly must be removed.
4. Remove the power steering speed sensor from the gearbox without disconnecting the power steering hose.
5. Remove the shift cable and selector cable from the upper gearbox cover. Loosen the cable holder mounting bolt. Do not bend the cables more than necessary. Remove the cables together with their holder.
6. Remove the upper transmission mounting bracket. Remove the four transmission-to-engine block mounting bolts. The bolts are removed through the engine bay.
7. Raise and securely support the vehicle. Remove both front wheels and the mudguard.
8. Drain the transmission fluid into a drain pan. Remove the clutch slave cylinder. The cylinder can be pulled out without disconnecting the hose.
9. Remove the center beam. Completely pull out the right torque rod. Remove the right and left drive shafts (half shafts).
10. Remove the engine stiffener. Remove the clutch housing. Support the gearbox with a jack.
11. Remove the three lower bolts from the rear engine mount. Loosen, but do not remove, the top bolt, which will support the weight of the engine.
12. Remove the two remaining bolts securing the gearbox to the engine.
13. Raise the gearbox with a jack, disconnect the input shaft from the clutch disc and remove the gearbox from the vehicle.
WARNING: Do not leave the gearbox hanging on the input shaft. Remove the gearbox completely and in one go.
To install:
14. Support the gearbox with a jack. Clean and lubricate the sliding surface of the release bearing.
15. Check that the two dowel pins are in place in the clutch housing.
16. Raise the assembly until the pins are flush with the input sockets in the cylinder block.
17. Insert the mounting bolts from the engine side. Tighten them to 65 Nm.
18. Insert the mounting bolts from the gearbox side. Tighten them to 65 Nm.
19. Install the gearbox mounting bracket. Tighten the three bolts to 39 Nm and the horizontal bolt to 75 Nm.
20. Insert the gearbox mounting bolts into the rear engine mount and tighten them to 75 Nm.
21. Install the engine stiffener and tighten its bolts one by one to a torque of 39 Nm.
22. Attach the secondary shaft.
23. Install the drive shafts.
24. Install the center beam and tighten the bolts to 51 Nm.
25. Install the clutch slave cylinder and tighten the mounting bolts to 22 Nm.
26. Connect the shift and selector cables to the gearbox.
27. Connect the reversing light wiring.
28. Install the right and left shock absorber forks.
29. Install the speed sensor assembly.
30. Install the air cleaner box if it was removed.
31. Connect the starter and battery ground wires.
32. Connect the wire to the positive terminal of the battery.
33. Install the front wheels.
34. Fill the gearbox with the required amount of oil.
35. Check how smoothly the clutch and gearshift lever operate. Adjust their operation if necessary.