Main Shaft
MAIN SHAFT ASSEMBLYNOTE:
^ Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear.
^ Use new circlips; on shaft for installation. Don't reuse circlips.
1. Assemble high speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
a. Slide hub (3) in sleeve (4) so that wider flange side of sleeve (4) and boss side of hub (3) face opposite as shown in the figure, also aligning hub slots with key location teeth of sleeve (4).
b. Insert keys (2) in hub slots with depression side of keys face center of hub (3).
c. Install springs (1) to internal circle of key locations with spring end gaps apart at angles about 120 degrees each other, in order to apply spring tension equally to each key.
NOTE: Do not mix high and low speed synchronizer keys as dimensions are different.
2. Install synchronizer ring (1) by matching its key slots to keys as shown in the figure.
3. Insert 3rd gear, (2) needle bearing (3) and high speed sleeve/hub assembly (4) with synchronizer ring to main shaft (1).
4. Press-fit high speed sleeve/hub assembly (1) with special tool and press (2).
Special tool (A): 09940-53111
5. Select circlip (1) that will make thrust clearance of clutch hub 0.1 mm (0.0039 inch) or less and install it.
Circlip thickness specification:
Special tool (B): 09900-06107
6. After installing circlip, check that 3rd gear turns lightly.
7. Check 3rd gear (2) thrust clearance by using thickness gauge (1). If clearance is out of specification, repress-fit or replace.
3rd gear thrust clearance:
Standard: 0.10 - 0.25 mm (0.004 - 0.009 inch)
8. Assemble low speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
a. Slide hub (3) in sleeve (4) with aligning hub slots with key location teeth of sleeve (4).
b. Insert keys (2) in hub slots with depression side of keys (2) face center of hub (3).
c. Install springs (1) to internal circle of key locations with spring end gaps apart at angles about 120 degrees each other, in order to apply spring tension equally to each key.
NOTE: Before Installing hub (3), sleeve (4), springs (1) and keys (2) assembly to main shaft, there is no specific Installation direction on each component. However, when Installing assembly to main shaft, gear side of sleeve (4) should face to forward direction as shown in the figure.
9. Install synchronizer ring (1) by matching its key slots to keys as shown in the figure.
10. Insert 2nd gear (2), needle bearing (3) and low speed sleeve/hub assembly (4) with synchronizer ring to main shaft (1).
11. Press-fit low speed sleeve/hub assembly with special tool and press (1).
Special tool (A): 09940-53111
12. Check 2nd gear thrust clearance.
13. Apply grease to ball (1) and set it to main shaft (3).
14. Install synchronizer ring (2).
15. Install needle bearing (2), low gear (3) and needle bush (1) to main shaft.
NOTE:
^ Check the cut in needle bush and ball are engaged.
^ After installation, check the synchronizer ring (4) moves in circumferential direction.
16. Press-fit main shaft bearing (1) and 5th gear with special tools and press (2).
NOTE: Bring bearing so that its groove for circlip is in the rear.
Special tool (C): 09940-51710 or 09925-18011
17. Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 inch) or less and install it.
Circlip thickness specification:
18. Check low gear clearance.