91531-SZ5-003 Honda CLIP, TUBE (3.5)

The gearbox has a drive plate which is bolted to the flywheel and splined to an input shaft. The input shaft is splined to an input gear which meshes with three drive gears. One drive gear is splined to the cutter drive shaft and the other two gears are splined to the wheel drive and auxiliary cutter pump shafts. The engine turns the drive plate, input shaft and input gear. The input gear turns the drive gears, drive shaft and pump shafts. The pump shafts and drive shaft turn in the direction opposite the engine, at a speed slower than the engine by the ratio 1.27 to 1. The input gear and drive gears are straddle mounted in ball bearings.Lubrication
The oil level in the gearbox should be kept at check plug level to ensure proper lubrication of internal components.Under normal operating conditions the SAE 90 gear lubricant (GL) specified in "Service Data" should be used; however the lubricant should be changed if the operating temperatures are higher or lower than normal: 1. If the gearbox case temperature is consistently above 220°F, (104°C), use an SAE 140 gear lubricant.2. If the atmospheric temperature is 30°F (-1.1°C) and above, use an SAE 90 gear lubricant.3. If the atmospheric temperature is 50°F (9.9°C) and below, use an SAE 30 gear lubricant.Internal and external splines should be liberally greased whenever the input shaft, cutter drive shaft or a hydraulic pump is replaced.Removing The Gearbox
INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.
1. Remove the upper pump cowling and upper radiator grill.2. Remove the air stack and muffler as necessary, then unbolt and remove as a unit the pump cowling, engine cowling and radiator cowling. 3. Close the shutoff valves in the pump supply lines.
MACHINES 504103 - 504108
MACHINES 504109 & SUBSEQUENT4. If the machine is not equipped with an auxiliary cutter, skip this step and step 5. Otherwise, thoroughly clean around the auxiliary cutter drive pump and hose connections, mark the hoses for identification during reassembly, then disconnect the hoses from the pump. Cap or plug all openings immediately.5. Attach a lifting device and support the weight of the cutter drive pump, approximately 39 pounds (17.7 kg). Remove the mounting bolts, pull the pump straight back until the pump shaft is clear of the gearbox, then move the pump away.6. Remove the cutter drive shaft (see Cutter 3.0-7 or Cutter 3.0-11).7. Thoroughly clean around the wheel drive pump and hose connections, mark the hoses for identification during reassembly, then disconnect the hoses from the pump. Do not disconnect any hoses or lines that run from one part of the pump to another. Cap or plug all openings immediately.8. Disconnect the wheel drive pump control cable mounting bracket and cable from the pump and lay them aside where they will not be damaged. DO NOT ALTER THE CONTROL CABLE ADJUSTMENT.9. Attach a lifting device and support the weight of the wheel drive pump, approximately 135 pounds (61.2 kg). Remove the mounting bolts, pull the pump straight back until the pump shaft is clear of the gearbox, then move the pump away.10. Attach a lifting device and support the weight of the pump drive gearbox, approximately 230 pounds (104.4 kg).11. Remove the mounting bolts from the flywheel cover and gearbox adjustment blocks, pull the gearbox straight back until the input shaft is clear of the drive plate, then lift the gearbox straight up and away.12. Move the gearbox to a place where it can be worked on.Disassembling The Gearbox
PUMP DRIVE GEARBOX MACHINES 504103 - 5041081. If the adaptor sleeves stayed with the gearbox, remove them.2. Remove the input shaft, flywheel cover and input gear from the gearbox.3. Remove the pump adapter plates from the gearbox.4. Remove the drive gears from the gearbox. The gears will remain with their bearings as sub-assemblies.5. Remove the bearings from the gears with a puller.6. Inspect the case for cracks or other damage, especially around bolt holes and shoulders that support bearings.7. Clean and inspect gears for chipped, broken or cracked teeth or splines.8. Clean and inspect the bearings.Assembling The Gearbox
Reassemble in reverse order of disassembly. Turn the input shaft by hand to ensure that the unit is free running. (Any binding of bearings in housing bores will load the bearings endwise and cause excessive heat when running.) Use all new gaskets, seals and O-rings. Cover openings to keep dirt out of the gearbox. FUNK PUMP DRIVE GEARBOX MODEL 28211, SPEC 2588A (CMI NO. 4-13532) MACHINES 504103 - 504108 Installing The Gearbox
INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.
1. Attach a lifting device to the pump drive gearbox. The gearbox weighs approximately 230 pounds (104.4 kg).2. Move the gearbox into position at the rear of the engine. Align the splines on the input shaft with the splines on the drive plate, then move the gearbox until the flywheel cover is flush with the flywheel housing. Install the mounting bolts in the flywheel cover and gearbox adjustment blocks.3. Attach a lifting device to the wheel drive pump. The pump weighs approximately 135 pounds (61.2 kg).4. Move the pump into position near the gearbox, coat the pump shaft with non-corrosive grease, position the O-ring, insert the shaft into the gearbox, and install the mounting bolts.5. Install the cutter drive shaft (see Cutter 3.0-9 or Cutter 3.0-16).6. If the machine is equipped with an auxiliary cutter, attach a lifting device to the auxiliary cutter drive pump. The pump weighs approximately 39 pounds (17.7 kg). Move the pump into position, coat the pump shaft with non-corrosive grease, position the O-ring, insert the shaft into the gearbox, and install the mounting bolts.7. Thoroughly clean around the pump ports and hydraulic hose ends, then connect the hoses to the pumps. 8. Open the shutoff valves in the pump supply lines, loosen the supply hose connection at each pump until air-free hydraulic