Secondary Shaft Clearance Inspection
Inspection1. Remove the O-rings from the secondary shaft.
2. Assemble the thrust needle bearing (A), 1st gear assembly (B), needle bearings (C), thrust needle bearing (D), 38 x 56.5 mm splined washer (E), 32 mm cotters (F), cotter retainer (G), and snap ring (H) on the secondary shaft (I).
3. Measure the clearance between the 38 x 56.5 mm splined washer (E) and cotters (F) with a feeler gauge (J) in at least three places. Use the average as the actual clearance.
4. If the measurement is out of standard, remove the splined washer, and measure its thickness.
5. Select and install a new splined washer, then recheck the clearance.
6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft.
7. Assemble the 1st/1st-hold/2nd clutch assembly (A), 37 x 55 mm thrust washer (B), thrust needle bearing (C), needle bearings (D), 2nd gear (E), thrust needle bearing (F), and 27 x 47 x 5 mm thrust washer (removed from mainshaft) (G) on the secondary shaft sub-assembly (H).
8. Set the dial indicator (1) on the 2nd gear (E).
9. Hold the 27 x 47 x 5 mm thrust washer (G) against the clutch assembly (A), and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear (E). Use the average as the actual clearance.
10. If the measurement is out of standard, remove the 37 x 55 mm thrust washer and measure its thickness.
11. Select and install a new thrust washer, then recheck the clearance.
12. Disassemble the shaft and gears.
13. Reinstall the 27 x 47 x 5 mm thrust washer on the mainshaft.