With One Touch 2-4 Selector System

DISASSEMBLY





1. Inspect drive sprocket thrust clearance.
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard Clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Maximum Clearance: 0.25 mm (0.0098 inch)
If the clearance exceeds the maximum, replace the drive sprocket.





2. Remove high and low clutch sleeve assembly.
a. Using a snap ring expander, remove the snap ring.
b. Remove the clutch sleeve and 3 shifting keys.
c. Using a press, remove the clutch hub, 2 key springs and key retainer.





3. Remove bearing, spacer and drive sprocket with front drive clutch sleeve assembly.
a. Using SST 09555-55010 and a press, remove the bearing.





Remove these parts.
^ Spacer and ball.
^ Drive sprocket with front drive clutch sleeve assembly.
^ Needle roller bearing.
^ Synchronizer outer ring, center ring and inner ring.
c. Remove the front drive clutch sleeve assembly from the drive sprocket.
4. Remove 3-shifting keys and 2 key springs from front drive clutch sleeve.

INSPECTION





1. Inspect rear output shaft.
Using a micrometer, measure the outer diameter of the rear output shaft journal surface.
Minimum Diameter:
Part A: 27.98 mm (1.1016 inch)
Part B: 36.98 mm (1.4561 inch)





2. Inspect drive sprocket radial clearance.
Using a dial indicator, measure the radial clearance between the sprocket and shaft with the needle roller bearing installed.
Standard Clearance: 0.010 - 0.055 mm (0.0004 - 0.0022 inch)
Maximum Clearance: 0.055 mm (0.0022 inch) If the clearance exceeds the Maximum, replace the drive sprocket, rear output shaft or needle roller bearing.





3. Inspect front drive shift fork and clutch sleeve clearance.
Using a feeler gauge, measure the clearance between the front drive shift fork and clutch sleeve.
Maximum Clearance: 1.0 mm (0.039 inch) If the clearance exceeds the Maximum, replace the shift fork or clutch sleeve.





4. Inspect high and low shift fork and clutch sleeve clearance.
Using a feeler gauge, measure the clearance between the high and low shift fork and clutch sleeve.
Maximum Clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the Maximum, replace the shift fork or clutch sleeve.

ASSEMBLY





1. Install front drive clutch sleeve onto drive sprocket.
a. Install the front drive clutch sleeve onto the drive sprocket.

HINT: Make sure to install the clutch sleeve in the correct direction.





b. Install the 3 shifting keys and 2 springs.

NOTICE: Install the key springs positioned so that their end gaps are not in line.





2. Install drive sprocket with front drive clutch sleeve assembly, spacer and bearing.





a. Apply gear oil to the shaft and needle roller bearing.
b. Install the synchronizer inner ring, center ring and outer ring.

NOTICE: Align the slots of outer and inner rings.





c. Install the needle roller bearing in the drive sprocket.
d. Install the drive sprocket with the front drive clutch sleeve assembly.
e. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
f. Install the spacer to align it with the ball.





g. Using Special Service Tool (SST) 09316-60011 (09316-00011, 09316-00071) and a press, install a new bearing with the outer race snap ring groove toward the rear.





3. Inspect drive sprocket thrust clearance.
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard Clearances. 0.10 - 0.25 mm (0.0039 - 0.0098 inch)





4. Insert high and low clutch hub onto clutch sleeve.
a. Install the clutch hub and 3 shifting keys onto the clutch sleeve.
b. Install the-2-shifting key springs under the shifting keys.

NOTICE: Install the key springs positioned so that their end gaps are not in line.





5. Install high and low clutch hub assembly.
Using SST 09316-60011 (09316-00011) and a hammer, drive in a new key retainer.

NOTICE: Be careful not to deform or damage the key retainer.





b. Using a press, install the high and low clutch hub assembly.





6. Install snap ring.
Select a snap ring that will allow minimum axial play and install it to the shaft.
Mark: Thickness
A: 2.10 - 2.15 mm (0.0827 - 0.0846 inch)
B: 2.15 - 2.20 mm (0.0846 - 0.0866 inch)
C: 2.20 - 2.25 mm (0.0866 - 0.0886 inch)
D: 2.25 - 2.30 mm (0.0886 - 0.0906 inch)
E: 2.30 - 2.35 mm (0.0906 - 0.0925 inch)
F: 2.35 - 2.40 mm (0.0925 - 0.0945 inch)
G: 2.40 - 2.45 mm (0.0945 - 0.0965 inch)
H: 2.45 - 2.50 mm (0.0965 - 0.0984 inch)
J: 2.50 - 2.55 mm (0.0984 - 0.1004 inch)
K: 2.00 - 2.05 mm (0.0787 - 0.0807 inch)
L: 2.05 - 2.10 mm (0.0807 - 0.0827 inch)