Input Shaft
RA60 MANUAL TRANSMISSION: INPUT SHAFT: INSPECTION
1. INSPECT INPUT SHAFT
(a) Using a dial indicator and 2 V-blocks, measure the shaft runout.
Maximum runout:
0.03 mm (0.0012 in.)
If the runout exceeds the maximum, replace the input shaft.
(b) Using a micrometer, measure the outer diameter of the input shaft journal surface.
Standard:
Minimum:
If the outer diameter is less than the minimum, replace the input shaft.
2. INSPECT 6TH GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 6th gear.
Standard inside diameter:
51.015 to 51.040 mm (2.0085 to 2.0095 in.)
Maximum inside diameter:
51.040 mm (2.0095 in.)
If the inside diameter exceeds the maximum, replace the 4th gear.
3. INSPECT 3RD GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 3rd gear.
Standard inside diameter:
51.015 to 51.040 mm (2.0085 to 2.0095 in.)
Maximum inside diameter:
51.040 mm (2.0095 in.)
If the inside diameter exceeds the maximum, replace the 3rd gear.
4. INSPECT 4TH GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 4th gear.
Standard inside diameter:
51.015 to 51.040 mm (2.0085 to 2.0095 in.)
Maximum inside diameter:
51.040 mm (2.0095 in.)
If the inside diameter exceeds the maximum, replace the 4th gear.
5. INSPECT NO. 2 TRANSMISSION HUB SLEEVE
(a) Check the sliding condition between the transmission hub No. 2 and transmission hub sleeve No. 2.
(b) Check that the spline gear teeth of the transmission hub sleeve No. 2 are not worn.
(c) Using vernier calipers, measure the width of the transmission hub sleeve No. 2 groove (A) and the thickness of the claw part on the gear shift forks No. 2 or No. 3 (B), and calculate the clearance.
Standard clearance:
(A - B);
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
If the clearance is outside the specification, replace the transmission hub sleeve No. 2 and gear shift fork.
6. INSPECT NO. 3 SYNCHRONIZER RING (FOR 6TH GEAR)
(a) Using a feeler gauge, measure the clearance between the synchronizer ring and the 6th gear.
Standard clearance:
0.70 to 1.50 mm (0.0276 to 0.0591 in.)
Minimum clearance:
0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
(b) Coat the 6th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 6th gear cone. Check that the ring locks.
7. INSPECT NO. 2 SYNCHRONIZER RING SET
(a) Using a feeler gauge, measure the clearance between the synchronizer ring and the 3rd gear.
Standard clearance:
Inner
1.20 to 2.20 mm (0.0472 to 0.0866 in.)
Middle
0.60 to 1.80 mm (0.0236 to 0.0709 in.)
Outer
0.80 to 1.80 mm (0.0315 to 0.0709 in.)
Minimum clearance:
Inner
1.20 mm (0.0472 in.)
Middle
0.60 mm (0.0236 in.)
Outer
0.80 mm (0.0315 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
(b) Coat the 3rd gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 3rd gear cone. Check that the ring locks.
8. INSPECT NO. 3 SYNCHRONIZER RING (FOR 4TH GEAR)
(a) Using a feeler gauge, measure the clearance between the synchronizer ring and 4th gear.
Standard clearance:
0.70 to 1.50 mm (0.0276 to 0.0591 in.)
Minimum clearance:
0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
(b) Coat the 4th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the 4th gear cone. Check that the ring locks.
9. INSPECT 3RD GEAR THRUST WASHER
(a) Using a micrometer, measure the thrust washer thickness.
Standard thickness:
7.12 to 7.18 mm (0.2803 to 0.2827 in.)
Minimum thickness:
7.12 mm (0.2803 in.)
If the thickness is less than the minimum, replace the thrust washer.