Countershaft and Reverse Idle Gear

Disassembly





1) Remove circlip (1) from countershaft.





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.





3) Select circlip that will make its thrust clearance 0.1 mm (0.0039 inch) or less and install it.





Circlip thickness specification

Inspection





^ Using micrometer, check diameter of counter shaft as shown. If measured valve is out of specification, replace it.





^ Check clearance between fork and sleeve. If clearance exceeds limit, replace fork and sleeve.





^ 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.





^ Using cylinder gauge (1), check inside diameter of countershaft 5th gear (2). If measured value exceeds specification, replace gear.





^ 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.





^ Check clearance between reverse idle gear (2) and shoe (1) of reverse gear shift link. If clearance exceeds limit, replace shoe.