Step 3

ASSEMBLY-STEP 3
Assemble in the sequence shown in the image.







Synchronizer Key

NOTE: There are two (2) types of synchronizer key.





NOTE: Align the synchronizer ring groove and clutch hub key when installing.




(PRIMARY SHAFT GEAR)
Bearing Inner Race
Install the bearing inner race with the SST




Clutch Hub Assembly (3rd-4th gear)
1. Install 3rd gear and synchronizer ring.
2. Set the clutch hub assembly as shown in the image.




3. Install the clutch hub assembly with the SST.




4. Install the retaining ring.




4th Gear
1. Install the 4th gear and synchronizer ring
2. Install the bearing inner race with the SST




(SECONDARY SHAFT GEAR)
Bearing Inner Race
Install the bearing inner race with the SST.




NOTE: The styles and size of the synchronizer rings are different as shown in the illustration.




1. Install the 1st gear and synchronizer ring.
2. Install the clutch hub assembly with the SST.




3. Install the retaining ring.




2nd Gear
1. Install the synchronizer ring and 2nd gear.
2. Install the secondary 3rd gear with the SST.




3. Install the retaining ring.




Secondary 4th Gear
1. Install the secondary 4th gear.
2. Install the bearing inner race with the SST.




Thrust Clearance of 3rd Gear
Measure the clearance between the 3rd gear and the primary shaft gear.
Standard: 0.050-0.200 mm (0.002-0.008 in)
Maximum: 0.250 mm (0.039 in)




Thrust Clearance of 4th Gear
Measure the clearance between the 4th gear and the bearing inner race.
Standard: 0.165-0.365 mm (0.006-0.014 in)
Maximum: 0.415 mm (0.0163 in)




Thrust Clearance of 1st Gear
Measure the clearance between the 1St gear and the differential drive gear on the secondary shaft.
Standard: 0.050-0.280 mm (0.002-0.011 in)
Maximum: 0.330 mm (0.013 in)




Thrust Clearance of 2nd Gear
Measure the clearance between the 2nd gear and the secondary 3rd gear.
Standard: 0.175-0.455 mm (0.007-0.018 in)
Maximum: 0.505 mm (0.0199 in)




Shift Fork
Install both shift forks and the interlock sleeve as in the image.