Inspection

Check each of the items listed below, and repair or replace any if necessary.

Transmission case and housing
1. Cracks, damage, or wear
2. Rough contact surfaces or damage




Each gear and main drive gear
1. Worn or damaged synchronizer cones
2. Worn or damaged hub sleeve parts
3. Worn or damaged teeth
4. Worn or damaged inner gear or outer gear surfaces
5. Worn or damaged main drive gear splines





Mainshaft
1. Runout: Maximum 0.20 mm (0.0079 in)
2. Worn or damaged splines
3. Worn or damaged meshed part of each gear
4. Worn or damaged coupling to main drive gear




Countershaft
1. Worn or damaged gear teeth
2. Worn or damaged splines
3. Worn or damaged friction gears




Reverse idle gear and shaft
1. Worn or damaged gear
2. Worn shaft
Standard clearance: 0.02 - 0.05 mm (0.0008 - 0.0020 in)
Maximum: 0.15 mm (0.0059 in)




Synchronizer ring
1. Gear cone mesh
2. Worn or damaged splines
3. Worn or damaged taper surface




4. Clearance between synchronizer ring and flank surface of gear

Standard clearance: 1.5 mm (0.059 in)
Maximum: 0.8 mm (0.031 in)

NOTE: Set the synchronizer ring straight in the gear, and measure around the circumference.




Clutch hub
1. Operation of clutch hub sleeve and hub
2. Worn or damaged hub sleeve sliding surface
3. Worn or damaged hub synchronizer key groove
4. Worn gear teeth




Clutch hub sleeve
1. Worn or damaged clutch hub sliding surfaces.
2. Clearance between hub sleeve and release fork.

Standard clearance: 0.2 - 0.3 mm (0.008 - 0.012 in)

Maximum: 0.5 mm (0.020 in)




Control lever and shift rod
1. Clearance between the control lever and the gate of the shift rod

Clearance: 0.8 mm (0.0315 in) max.




Synchronizer key and key spring
1. Worn key
2. Fatigued or damaged spring




Bearing
1. Roughness or noise while turning
2. Damaged bearing
3. Worn bearing