Part 1
CASE COMPONENTS
GEAR COMPONENTS
DISASSEMBLY
1. Before removing transmission case, remove bolts and plugs as shown.
2. Remove transmission case.
3. Remove position switch.
4. Mesh 4th gear, then remove reverse idler shaft and reverse idler gear.
5. Pull out retaining pin.
6. Remove reverse lever spring and reverse lock spring from reverse lever assembly.
7. Remove reverse arm shaft while rotating it.
8. Remove reverse lever assembly.
9. Remove 5th & reverse check plug, spring and ball.
10. Remove stopper rings and retaining pins from 5th & reverse and 3rd & 4th fork rods.
11. Remove 5th & reverse and 3rd & 4th fork rods. Then remove forks and brackets.
12. Remove input shaft and mainshaft with 1st & 2nd fork and fork rod as a set.
13. Remove final drive assembly.
CAUTION: Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.
14. Remove reverse check assembly.
- Be careful not to lose check ball.
15. Remove retaining pin with Tool and detach the selector.
16. Remove drain plug for convenience in removing retaining pin which holds striking lever to striking rod.
17. Remove retaining pin with Tool and then withdraw striking lever and striking rod.
REPAIR FOR COMPONENT PARTS
INPUT SHAFT AND GEARS
DISASSEMBLY
1. Before disassembly, check 3rd, 4th and 5th input gear end plays.
- If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove. Refer to Assembly.
2. Remove input shaft rear bearing with Tool.
3. Remove 5th & reverse synchronizer and 5th input gear with Tool.
4. Remove thrust washer ring, thrust washers and 4th input gear.
5. Remove snap ring.
6. Remove 3rd & 4th synchronizer and 3rd input gear with Tool.
7. Remove input shaft front bearing with Tool.
INSPECTION
GEAR AND SHAFT
- Check shaft for cracks, wear and bending.
- Check gears for excessive wear, chips and cracks.
SYNCHRONIZER
- Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks and deformation.
- Check insert springs for wear and deformation.
- Measure clearance between baulk ring and gear (3rd, 4th and 5th).
Clearance between baulk ring and gear: Refer to image.
- Measure wear of reverse baulk ring.
a. Place reverse baulk ring on Tool and then place reverse synchronizer cone on reverse baulk ring.
- Make sure projection of synchronizer cone is positioned over the recess on Tool.
b. While holding reverse synchronizer cone against reverse baulk ring as firmly as possible, measure dimension "A" with dial indicator.
c. If dimension "A" is smaller than the wear limit, replace baulk ring.
BEARING
- Make sure bearings roll freely and are free from noise, cracks, pitting and wear.
ASSEMBLY
1. Place inserts in three grooves on coupling sleeve (3rd & 4th synchronizer).
2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.
- Pay attention to its direction.
4. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove.
Then install them and thrust washer ring.
Allowable clearance of groove: 0 - 0.06 mm (0 - 0.0024 inch)
7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.
b. Install insert springs with reverse baulk ring onto coupling sleeve.
- Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.
e. Place reverse synchronizer assembly on 5th input gear.
- Mesh recesses of 5th input gear with projections of reverse synchronizer cone.
- Put insert spring mounts on reverse baulk ring upon those on 5th baulk ring.
f. Press on 5th & reverse synchronizer assembly with 5th input gear.
8. Install input shaft front and rear bearings with Tool.
9. Measure gear end play as the final check.