Inspection

Inspect all parts and repair or replace as necessary.




Synchronizer Ring
1. Inspect the synchronizer ring teeth for damage, wear, and cracks.
2. Inspect the tapered surface for wear and cracks.




3. Set the synchronizer ring squarely in the gear.
4. Measure the clearance between the synchronizer ring and flank surface of the gear all around the circumference.

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: 0.10 - 0.32 mm (0.004 - 0.013 in)
Maximum: 0.37 mm (0.015 in)




Primary Shaft Gear
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for blockage.
5. Measure the shaft gear runout.

Maximum runout: 0.05 mm (0.002 in)

6. If the shaft gear is replaced, adjust the bearing preload.










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




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




Bearing
Inspect for damage and rough rotation.




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

Maximum runout: 0.015 mm (0.0006 in)

6. If the shaft gear is replaced, adjust the bearing preload.







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 gear teeth for damage, wear, and cracks.




Clutch hub assembly
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer keys for damage, wear, and cracks.







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