Fifth Gears

1. To seat countershaft L bearing cup to bearing cone, tap cup by using Special Tool (A): 09913-84510, or equivalent and plastic hammer.





2. Put a shim on bearing cup provisionally, place straight edge over it and compress it by hand through straight edge, and then measure "a" (Clearance between case surface and straight edge) by using feeler gauge.
Clearance "a": 0.08 - 0.12 mm (0.0032 - 0.0047 inch) (Shim protrusion)

3. By repeating above step, select a suitable shim which adjusts clearance "a" to specification and put it on bearing cup.





NOTE: Insert 0.1 mm (0.004 inch) feeler to know whether or not a shim fulfills specification quickly.





4. Place left case plate inserting its end in groove of shift guide shaft and then tighten it with 6 screws applied with thread lock cement.
"A": Thread lock cement
Tightening Torque (a): 9 Nm (78 inch lbs.)
A=B
C: Short Side (Inward)
D: Long Boss (Inward)
E: Key Way
F: Chamfered Spline (Inward)

NOTE: After tightening screws, make sure that counter shaft can be rotated by hand feeling some load.





5. Assemble 5th speed synchronizer sleeve and hub with keys arid springs.

NOTE: Short side C in keys, long boss D in hub and chamfered spline F in sleeve should face inward (5th gear side).





6. Install 5th gear to counter shaft facing machined boss A inward.





7. Install needle bearing to input shaft, apply oil then install 5th gear and Special Tool (B): 09927-76010, or equivalent to stop shaft rotation.

8. Install countershaft nut and tighten it to specification.
Tightening Torque (b): 70 Nm (51.0 ft. lbs.)





9. Remove special tool, then caulk nut at C with caulking tool and hammer.
10. Install synchronizer ring then ring spring.
11. Fit 5th gear shift fork to sleeve & hub assembly and install them into input shaft, shift shaft and shift guide shaft at once aligning hub oil groove A with shaft mark B.

NOTE: Long boss of hub faces inward (gear side).

CAUTION: Be careful not to pinch synchronizer ring spring by hub.





12. Drive in spring pin facing its slit A outward.
13. Install steel ball, tighten shift fork plug applied with thread lock cement.
"A": Thread lock 1322, or equivalent
Tightening Torque (c): 9 Nm (78 inch lbs.)

14. Fit hub plate and fix it with circlip.

CAUTION:
^ Coat shift fork plug with thread lock cement reasonably. If it is done to much, excess may interfere in ball movement and cause hard shift to 5th speed.
^ Make sure circlip is installed in shaft groove securely.





15. Clean mating surface of both left case and side cover, coat mating surface with sealant evenly, mate it with left case and then tighten with 8 bolts.
"B": Sealant
Tightening Torque for left cover bolts:
(a): 10 Nm (90 inch lbs.)
(b): 23 Nm (17.0 ft. lbs.)