Inspection of Components

INSPECTION OF TRANSFER COMPONENTS

1. INSPECT REAR OUTPUT SHAFT
(a) Check the rear output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the rear output shaft journal surface.
Minimum outer diameter:
Part A 40.009 mm (1.5752 in.)
B 40.009 mm (1.5752 in.)

2. CHECK OIL CLEARANCE OF LOW AND HIGH GEAR
(a) Using a dial indicator, measure oil clearance between the high gear and shaft.
Standard clearance: MTM 0.035 - 0.081 mm (0.0014 - 0.0032 in.)
ATM 0.019 - 0.068 mm (0.0007 - 0.0027 in.)
Maximum clearance: MTM 0.081 mm (0.0032 in.)
ATM 0.068 mm (0.0027 in.)

(b) Using a dial indicator, measure the oil clearance between the low gear and shaft.
Standard clearance: MTM 0.035 - 0.081 mm (0.0014 - 0.0032 in.)
ATM 0.019 - 0.068 mm (0.0007 - 0.0027 in.)
Maximum clearance: MTM 0.081 mm (0.0032 in.)
ATM 0.068 mm (0.0027 in.)

3. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeves and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)

4. IF NECESSARY, REPLACE REAR OUTPUT SHAFT PILOT BEARING
(a) Using SST, remove the rear output shaft pilot bearing. SST 09319-60020

NOTE: The bearing will break.

(b) Using SST, press in a new pilot bearing. SST 09608-20011
(c) Apply MP grease to the pilot bearing.

5. IF NECESSARY, REPLACE REAR OUTPUT SHAFT FRONT BEARING OUTER RACE
(a) Using SST, remove the rear output shaft front bearing outer race. SST 09514-35011

(b) Using SST, press a new front outer race into the front bearing retainer. SST 09316-60010

6. IF NECESSARY, REPLACE REAR OUTPUT SHAFT REAR BEARING OUTER RACE
(a) Using SST, remove the rear output shaft rear bearing outer race and shim. SST 09514-35011

(b) Install the thinnest shim into the rear bearing retainer.
(c) Using SST, press in a new rear outer race to the rear bearing retainer. SST 09316-60010

7. IF NECESSARY, REPLACE FRONT OUTPUT SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal.

(b) Using SST, drive in a new oil seal. SST 09316-60010
(c) Apply MP grease to the oil seal lip.

8. IF NECESSARY, REPLACE FRONT DRIVE SHIFT FORK SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal.

(b) Using SST, drive in a new oil seal. SST 09608-20011
(c) Apply MP grease to the oil seal lip.

9. IF NECESSARY, REPLACE TRANSMISSION REAR OIL SEAL
(a) Using a screwdriver, remove the transmission rear oil seal.

(b) Using SST, drive in a new oil seal. SST 09316-60010
(c) Apply MP grease to the oil seal lip.

10. IF NECESSARY, REPLACE REAR OUTPUT SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal.

(b) Using SST, drive in a new oil seal. SST 09316-60010
(c) Apply MP grease to the oil seal lip.

11. IF NECESSARY, REPLACE HIGH AND LOW GEAR SELECT LEVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.

(b) Using SST and hammer, drive in a new oil seal. SST 09608-20010
(c) Apply MP grease to the oil seal lip.

12. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL
(a) Using SST, pull out the oil seal. SST 09921-00010

(b) Using SST, drive a new oil seal into the sleeve. SST 09201-60011
Oil seal depth: 20 mm (0.79 in.)

13. IF NECESSARY, REPLACE FRONT OUTPUT SHAFT BEARING
(a) Remove the oil seal.
(b) Using a screwdriver, remove the snap ring.

(d) Using SST, press in a new bearing. SST 09316-60010

(e) Install the snap ring.
(f) Install a new oil seal.