Countershaft and Reverse Idler Gear

Disassembly





1. Remove circlip (1) from countershaft.
Special tool
(A): 09900-06107





2. Pull out bearing (3) from counter shaft by using bearing puller (4), press (1) and rod (diameter approximately 22 mm (0.87 inch)) (2)

Reassembly





1. Fit sleeve (4) to counter shaft 5th gear (3), place 3 synchronizer keys (2) in it and then set synchronizer springs (1). Refer to figure for proper installing direction of gear, sleeve and springs. Also, note that key has specific installing direction.





2. Set inner race (2) to counter shaft front bearing (1) and press-fit bearing with press and special tool.

NOTE: When installing bearing, bring it so that its groove for Circlip is in the front.

Special tool
(A): 09940-54950
3. Select circlip that will make its thrust clearance 0.1 mm (0.0039 inch) or less and install it.








Circlip thickness specification

Special tool
(B): 09900-06107

Countershaft and Reverse Idle Gear Inspection





^ Using micrometer, check diameter of counter shaft as shown. If measured valve is out of specification, replace it.
Countershaft diameter (standard)
"a": 25.986 - 26.000 mm (1.0231 - 1.0236 inch)
"b": 30.957 - 30.972 mm (1.2188 - 1.2194 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 - 0.014 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 (countershaft)
Standard: 1.0 - 2.0 mm (0.039 - 0.079 inch)
Limit: 0.8 mm (0.031 inch)
Key slot width "b", (countershaft)
Standard: 10.0 - 10.2 mm (0.394 - 0.402 inch)
Limit: 10.45 mm (0.411 inch)





^ Using cylinder gauge (1), check inside diameter of countershaft 5th gear (2). If measured value exceeds specification, replace gear.
Countershaft 5th gear diameter
Standard: 33.015 - 33.040 mm (1.2998 - 1.3008 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 (0.020 inch)