Inspection

Inspect all parts and repair or replace as necessary.




Synchronizer Ring
1. Inspect individual synchronizer ring teeth for damage, wear, cracks.
2. Inspect taper surface for wear or cracks.

NOTE: Set the synchronizer ring squarely in the gear; then measure around the circumference.




3. Measure the clearance between the synchronizer ring and flank surface of the gear.

Standard clearance: 1.12 - 1.88 mm (0.044 - 0.074 in.)
Minimum: 0.8 mm (0.032 in.)




Reverse Idler Gear and Reverse Lever
1. Inspect gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bushing and the reverse lever.

Standard clearance: 0.1 0 - 0.32 mm (0.004 - 0.013 in.)
Maximum: 0.37 mm (0.015 in.)




Primary Shaft

NOTE: If the shaft gear is replaced, adjust the bearing preload.

1. Inspect the shaft gear runout.

Maximum runout: 0.025 mm (0.001 in.)

2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.










3rd Gear, 4th Gear, 5th Gear, and Gear Sleeve (5th gear)
1. Measure the clearance between the shaft gears and gears.




2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.




Bearing
1. Inspect for damage or rough rotation.




Secondary Shaft

NOTE: If the shaft gear is replaced, adjust the bearing preload.

1. Inspect the shaft gear runout.

Maximum runout: 0.015 mm (0.001 in.)

2. Inspect the gear teeth for damage, wear, and cracks.










1st Gear and 2nd Gear
1. Measure the clearance between the shaft gears and the gears.
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.

Clutch hub assembly




1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the individual gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer key for damage, wear, and cracks.







4. Measure the clearance between the hub sleeve and the shift fork.