Inspection

Inspect all parts and repair or replace as necessary.




Gears
1. Inspect synchronizer cones for wear.
2. Inspect individual gear teeth for damage, wear, and cracks.
3. Inspect synchronizer ring matching teeth for damage and wear.




Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear, and cracks.
2. Inspect taper surface for wear and 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: 1.5 mm (0.059 in.)
Minimum: 0.8 mm (0.032 in.)




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 hub sleeve and shift fork.




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: 0.10 - 0.32 mm (0.004 - 0.013 in.)
Maximum: 0.5 mm (0.020 in.)




Bearing
1. Inspect for damage and rough rotation.




Primary Shaft and Secondary Shaft
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for clogging.
5. Inspect the shaft gears' runout.

Primary shaft gear runout: 0.05 mm (0.002 in.)




Secondary shaft gear runout: 0.015 mm (0.0006 in.)

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










6. Oil clearance between shaft gears and gears.




Speedometer Driven Gear Assembly
1. Inspect the teeth for damage and wear.
2. Inspect the O-ring for damage and wear.