Counter Shaft and Reverse Idler Gear

COUNTER SHAFT AND REVERSE IDLE GEAR





^ Using micrometer, check diameter of counter shaft as shown in the figure. If measured valve is out of specification, replace it.
Counter shaft diameter (standard)
"a": 25.986 - 26.00 mm (1.0231 - 1.0236 inch)
"b": 30.957 - 30.972 mm (1.2188 - 1.2193 inch)





^ Check clearance between fork and sleeve. If clearance exceeds limit, replace fork and sleeve.
Clearance between fork and sleeve:
Standard: 0.15 - 0.35 mm (0.006 - 0.013 inch)
Limit: 1.0 mm (0.039 inch)





^ Check clearance "a" between synchronizer ring and gear, key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Clearance "a" between synchronizer ring and gear (counter shaft):
Standard: 1.0 - 2.0 mm (0.039 - 0.078 inch)
Service limit: 0.8 mm (0.032 inch)
Key slot width "b" (counter shaft):
Standard: 10.0 - 10.2 mm (0.394 - 0.4015 inch)
Service limit: 10.45 mm (0.411 inch)





^ Using cylinder gauge (1), check inside diameter of counter shaft 5th gear (2). If measured value exceeds specification, replace gear.
Counter shaft 5th gear diameter:
Standard: 33.015 - 33.040 mm (1.2999 - 1.3007 inch)





^ Check oil clearance between reverse idle gear (2) and shaft (1) by measuring inside diameter of gear and diameter of shaft and calculate its clearance. If clearance exceeds limit, replace gear and shaft.
Oil clearance between reverse Idle gear and shaft
Standard: 0.040 - 0.082 mm (0.0016 - 0.0032 inch)
Limit: 0.13 mm (0.005 inch)





^ Check clearance between reverse idle gear (2) and shoe (1) of reverse gear shift link. If clearance exceeds limit, replace shoe.
Clearance between reverse idle gear and shoe
Standard: 0.05 mm - 0.28 mm (0.002 - 0.011 inch)
Limit: 0.5 mm (0.019 inch)