Fifth Gears

INSTALLATION





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





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 bolts applied with thread lock cement.

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

"A": Thread lock 1322, 99000-32110
Tightening Torque
(a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)





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





6. Install needle bearing to input shaft, apply oil then install input shaft 5th gear.
7. Engage gear double meshing to tighten counter shaft nut and tighten it to specified torque.
Tightening Torque
(a): 70 Nm (7.0 kg-m, 51.0 ft. lbs.)





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

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





9. Install synchronizer ring to input shaft 5th gear.
10. Fit 5th gear shift fork to sleeve & hub assembly and install them into input shaft, gear shift shaft and gear shift guide shaft at once aligning hub depression A, shaft mark B and synchronizer key C.

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





11. Install steel ball, tighten shift fork plug applied with thread lock cement.

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

"A": Thread lock 1322, 99000-32110
Tightening Torque
(a): 9 Nm (0.9 kg-m, 6.5 ft. lbs.)

12. Install circlip and C-ring.





13. Install 5th synchronizer hub plate to synchronizer hub by positioning it so that its lugs A fit into their depression B in synchronizer hub and its 2 small holes C come on the same side as cut D in input shaft.





14. Engage gear double meshing to tighten input shaft nut and tighten it to specified torque.
Tightening Torque
(a): 70 Nm (7.0 kg-m, 51.0 ft. lbs.)
15. Caulk input shaft nut and counter shaft nut with caulking tool.





16. 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": BOND No. 1215, 99000-31110
Tightening Torque for left cover bolts (a): 10 Nm (1.0 kg-m, 7.5 ft. lbs.)