Disassembly

DISASSEMBLY

Case Components





1. Remove rear extension upper cover mounting bolts.
2. Remove rear extension upper cover and rear extension upper cover gasket from the rear extension.





3. Remove check select spring and check ball from the rear extension.





4. Remove retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove control rod.
5. Remove neutral position switch, plunger and back-up lamp switch from the rear extension.





6. Remove control bracket mounting bolts. Then remove check shift pin and control bracket as one unit from the rear extension.





7. Remove right and left return spring plug. Then remove return spring and return spring plunger from the rear extension.

CAUTION: Return spring and return spring plunger have different lengths for right and left sides. Identify right and left side and then store.





8. Remove rear oil seal from the rear extension using an oil seal puller.
Tool number: KV381054S0 (-)





9. Remove rear extension mounting bolts. Using a soft hammer, tap rear extension assembly to remove.
10. Remove control lever housing mounting bolts, and remove control lever housing from the rear extension.
11. Remove striking rod oil seal from the rear extension.
12. Remove rear extension oil gutter from the rear extension.





13. Remove reverse idler thrust washer, revere idler gear, and reverse idler needle bearing from the reverse idler shaft.
14. Remove reverse idler shaft from the adapter plate.





15. Remove withdrawal lever ball pin and washer from the front cover.
16. Remove front cover mounting bolts, then remove front cover assembly and front cover gasket from the transmission case.





17. Remove front cover oil seal from the front cover assembly, using a flat-bladed screwdriver.

CAUTION: Be careful not to damage front cover mating surface.





18. Remove baffle plate mounting nut from the transmission case.





19. Remove snap ring from the main drive gear bearing, using snap ring pliers.





20. Using a soft hammer to carefully tap main shaft and counter shaft from the transmission case side, and then separate adapter plate and transmission case.





21. Remove counter front bearing from the transmission case.
22. Remove oil gutter from the transmission case.

Shift Control Components





1. Install adapter setting plate to the adapter plate and then fixing in adapter setting plate using a vise.
Tool number: ST224490000 (-)

CAUTION: Do not directly secure the surface in a vise.





2. Remove baffle plate mounting bolts, and remove baffle plate from the adapter plate.





3. Remove magnet from the adapter plate.
4. Remove retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove striking lever and striking rod.





5. Remove check ball plug and then remove check ball spring and check ball from the adapter plate.





6. Remove 3rd - 4th control lever mounting bolts and then remove 3rd - 4th control lever and shifter cap.





7. Remove check ball plug and then remove check ball spring and check ball from the adapter plate.





8. Using a pin punch [6 mm (0.24 inch) dia.] to knock out retaining pin, and then remove 3rd - 4th fork rod bracket and 3rd - 4th fork rod.





9. Using a pin punch [6 mm (0.24 inch) dia.] to knock out retaining pin, and then remove 3rd - 4th shift fork and 3rd - 4th fork rod (reversal side).





10. Remove check ball and interlock pin from the adapter plate.





11. Using a pin punch [6 mm (0.24 inch) dia.] to knock out retaining pin, and then remove 1st - 2nd shift fork and 1st - 2nd fork rod.





12. Remove interlock plunger and interlock pin from the adapter plate.





13. Using a pin punch [6 mm (0.24 inch) dia.] to knock out retaining pin, and then remove reverse shift fork and reverse fork rod.





14. Remove check ball from the adapter plate.





15. Remove 5th - 6th control lever mounting bolts and then remove 5th - 6th control lever from the adapter plate.





16. Using a pin punch [6 mm (0.24 inch) dia.] to knock out retaining pin, and then remove 5th - 6th fork rod bracket and 5th - 6th fork rod.





17. Using a pin punch [6 mm (0.24 inch) dia.] to knock out retaining pin, and then remove 5th - 6th fork rod (reversal side) and 5th - 6th shift fork.

Gear Components





^ Before disassembly, measure end play for each position. If the end play is outside the standards, disassemble and inspect.
- Main drive gear
End play: 0 - 0.10mm (0 - 0.004 inch)





- Main shaft
End play: 0 - 0.10 mm (0 - 0.004 inch)





- Counter shaft
End play: 0 - 0.10 mm (0 - 0.004 inch)





1. After removing snap ring and reverse coupling snap ring, using puller to remove reverse main gear and reverse synchronizer assembly.
2. Remove reverse main needle bearing.





3. Remove main shaft bearing retainer mounting bolts and then remove main shaft bearing retainer.





4. After removing snap ring, using the puller to remove reverse counter gear and counter rear bearing spacer.





5. Remove snap ring from the main shaft bearing.





6. Carefully tap main shaft with a plastic hammer and then remove main shaft, main drive gear, and counter shaft from adapter plate.
7. Remove pilot bearing spacer and main pilot bearing.





8. Remove counter rear bearing from the adapter plate.





9. Remove snap ring from the main drive gear using snap ring pliers.





10. Set the suitable puller on the main drive gear and then using a press to remove main drive gear bearing from the main drive gear.





11. Using a press to remove the reverse main gear bushing, main shaft bearing and 4th main gear.





12. Remove 3rd - 4th main spacer.
13. Using a press to remove 1st main gear and 3rd main gear.

CAUTION: Be careful not to damage the baulk ring.

14. Remove 1st needle bearing.





15. Using a press to remove 1st gear bushing, 1st - 2nd synchronizer assembly, and 2nd main gear.

CAUTION: Be aware that when using the press, if the main shaft gear positioner catches on the V-block, etc., the main shaft could be damaged.

16. Remove 2nd needle bearing.





17. After removing snap ring, using a press to remove 6th main gear and 5th - 6th synchronizer assembly.
18. Remove 6th needle bearing.





19. Using a press to remove the 3rd counter gear, 3rd - 4th synchronizer assembly, 4th counter gear, 4th needle bearing, 4th gear bushing, 4th counter gear thrust washer, and counter rear bearing inner race.
20. Remove 3rd needle bearing.





21. Using a press to remove the 3rd gear bushing.

INSPECTION AFTER DISASSEMBLY
Shift Control





If the contact surface on striking lever, fork rod, shift fork, etc. has excessive wear, abrasion, bend, or any other damage, replace the components.

Gear and Shaft








If the contact surface on each gear, main shaft, main drive gear, and counter shaft, etc. has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.

Synchronizer





^ If the contact surface on coupling sleeve, synchronizer hub, and shifting insert has damage or abrasion, replace the components.
^ Coupling sleeve and synchronizer hub shall move smoothly.





^ If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one.
^ If spread spring damaged, replace with a new one.

Baulk Ring Clearance





^ Single Cone Synchronizer (5th & 6th)
Push baulk ring on the cone and measure baulk ring back surface clearance at two locations or more on opposite sides, find the average value, and replace it if it is outside the limit value.
Clearance
Standard: 0.70 - 1.25 mm (0.028 - 0.049 inch)
Limit value: 0.5 mm (0.020 inch) or less
^ Double Cone Synchronizer (1st & 3rd & 4th)





Follow the instructions below and inspect the clearance of the outer baulk ring, synchronizer cone, inner baulk ring.

CAUTION: Clearances "A" and "B" of the outer baulk ring, synchronizer cone, and inner baulk ring are controlled as a set, so if the clearance is outside the limit value, replace the synchronizer assembly.





1. Using a dial gauge, measure clearance A at 2 or more points diagonally opposite, and calculate mean value.
Clearance A
Standard: 0.5 - 0.7 mm (0.020 - 0.028 inch)
Limit value: 0.3 mm (0.012 inch) or less
Tool number: ST30031000 (J22912 - 01)





2. Using a feeler gauge, measure clearance B at 2 or more points diagonally opposite, and calculate mean value.
Clearance B
Standard(1st): 1.0 - 1.5mm (0.039 - 0.059 inch)
Standard(3rd,4th): 0.85 - 1.35mm (0.033 - 0.053 inch)
Limit value: 0.7 mm (0.028 inch) or less





^ Triple cone synchronizer (2nd)
Check clearance for 2nd outer baulk ring, 2nd synchronizer cone, and 2nd inner baulk ring of triple cone synchronizer following the direction.

NOTE: 2nd outer baulk ring, 2nd synchronize cone, and 2nd inner baulk ring, three control "clearance A, B and C" as a three-piece suite. If the value exceeds the limit value, replace them as a three-piece suite.





1. Using feeler gauge put and press baulk ring on 2nd main gear taper cone, and then measure "clearance A" at more then 2 diagonal points, and calculate the average.
Clearance A
Reference value: 0.6 - 1.3 mm (0.024 - 0.051 inch)
Limit value: 0.3mm (0.012 inch) or less





2. Using feeler gauge measure "clearance B" at more than 2 diagonal positions, and calculate the average.
Clearance B
Reference value: 0.85 - 1.35 mm (0.033 - 0.053 inch)
Limit value: 0.7 mm (0.028 inch) or less





3. Using filler gauge put and press baulk ring on 2nd main gear taper cone, and then measure "clearance C" at more then 2 diagonal points, and calculate the average.
Clearance C
Reference value: 0.7 - 1.25 mm (0.028 - 0.049 inch)
Limit value: 0.3mm (0.012 inch) or less





^ Reverse Synchronizer
Push baulk ring on the cone and measure baulk ring back surface clearance at two locations or more on opposite sides, find the average value, and replace if it is outside the limit value.
Clearance
Standard: 0.75 - 1.2 mm (0.030 - 0.047 inch)
Limit value: 0.5 mm (0.020 inch) or less

Bearing





If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.