Inspection
Check the following parts, replace if necessary.
1st, 2nd, 3rd, 4th, and 5th gears
1. Worn or damaged synchronizer cone.
2. Worn or damaged hub sleeve coupling.
3. Worn or damaged teeth.
4. Worn or damaged inner surface or end surface of gears.
Primary Shaft Gear and Primary Gear
1. Worn or damaged gear contact surface.
2. Worn or damaged splines.
3. Worn teeth.
4. Clogged oil passage.
5. Primary shaft gear run-out.
Run-out: 0.200 mm (0.0079 in) max.
NOTE: If the shaft gear is replaced, adjust the bearing preload.
Outer diameter:
A. 41.975-41.991 mm (1.6526-1.6532 in)
B. 34.975-35.00 mm (1.3770-1.3780 in)
C. 31.675-31.700 mm (1.2470-1.2480 in)
Inner diameter (gears):
3rd. 47.00-47.02 mm (1.850-1.851 in)
4th. 47.00-47.02 mm (1.850-1.851 in)
5th. 43.00-43.02 mm (1.693-1.694 in)
Secondary Shaft Gear
1. Worn or damaged gear contact surface.
2. Worn or damaged splines.
3. Worn teeth.
4. Clogged oil passage.
5. Secondary shaft gear run-out.
Run-out: 0.03 mm (0.0012 in) max.
NOTE: If the shaft gear is replaced, adjust the bearing preload.
Outer diameter:
A. 42.975-42.991 mm (1.6919-1.6926 in)
B. 37.175-37.191 mm (1.4636-1.4642 in)
Inner diameter (gears):
1st. 48.00-48.02 mm (1.890-1.891 in)
2nd. 50.00-50.02 mm (1.969-1.969 in)
Bearing
1. Roughness or noise while turning.
2. Damaged bearing
3. Worn bearing.
Synchronizer Ring
1. Engagement with gear.
2. Worn or damaged teeth.
3. Worn or damaged tapered surface.
4. Clearance from the side of gear.
Clearance: 1.5 mm (0.059 in)
Minimum : 0.8 mm (0.032 in)
NOTE
- Place the synchronizer ring on the gear cone and rotate until it stops (approx. 10 to 20 degrees), then measure around the circumference.
- If the clearance is less than specified replace the synchronizer ring or gear.
Clutch Hub
1. Worn or damaged splines.
2. Worn or damaged synchronizer key groove.
3. Worn end surface.
4. Operation of the hub sleeve when installed.
Clutch Hub Sleeve
Clearance:
1. Worn or damaged hub splines.
2. Worn or damaged sleeve fork groove.
3. Clearance between sleeve and shift fork.
Reverse Idle Gear
1. Worn or damaged bushing.
2. Worn or damaged teeth.
3. Worn or damaged reverse shift lever coupling groove.
4. Clearance between sleeve and reverse shift lever.
Clearance: 0.09 mm - 0.318 mm (0.004-0.013 in)
Maximum: 0.368 mm (0.015 in)
Speedometer Driven Gear Assembly
Worn or damaged teeth.
Speedometer Drive Gear
Worn or damaged teeth.