Output Shaft: Testing and Inspection

1. Inspect output shaft.





a. Using a micrometer, measure the output shaft flange thickness.
Minimum thickness: 4.70 mm (0.1850 inch)
If the thickness is less than the minimum, replace the output shaft.





b. Using a micrometer, measure the outer diameter of the output shaft journal.
Minimum diameter:
A 1st gear: 38.860 mm (1.5299 inch)
B 2nd gear: 46.860 mm (1.8449 inch)
C 3rd gear: 37.860 mm (1.4905 inch)
If the outer diameter is less than the minimum, replace the output shaft.





c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 inch)
If the runout exceeds the maximum, replace the output shaft.
2. Inspect 1st and 3rd gears synchronizer ring.
a. Check for wear or damage.





b. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

c. Check again the braking effect of the synchronizer ring.





d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 inch)
If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

3. Inspect 2nd gear synchronizer ring.
a. Check for wear or damage.





b. Install the synchronizer inner ring, middle ring and outer ring to each gear.





c. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring.





d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 inch)
If the clearance is less than the minimum, replace the synchronizer ring.





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