Disassembly

DISASSEMBLY
Case Components





1. Remove rear extension upper cover mounting bolts, rear extension upper cover and rear extension upper cover gasket from rear extension.





2. Remove check select spring and check ball from rear extension.





3. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove control rod.
4. Remove neutral position switch, plunger and back-up lamp switch from rear extension.





5. Remove control bracket mounting bolts. Then remove check shift pin and control bracket as one unit from rear extension.





6. Remove right and left return spring plugs. Then remove return spring and return spring plunger from rear extension.

CAUTION: Return springs and return spring plungers have different lengths for right and left sides. Identify right and left side and then store.





7. Remove rear oil seal from rear extension using the oil seal puller.
Tool number : KV381054S0 ( - )





8. Remove rear extension mounting bolts. Using a soft hammer, tap rear extension assembly to remove.
9. Remove control lever housing mounting bolts and control lever housing from rear extension.
10. Remove striking rod oil seal from rear extension. Refer to CASE COMPONENTS.
11. Remove rear extension oil gutter mounting bolt and rear extension oil gutter from rear extension. Refer to CASE COMPONENTS.





12. Remove reverse idler thrust washer, reverse idler gear and reverse idler needle bearing from reverse idler shaft.
13. Remove reverse idler shaft from adapter plate.





14. Remove withdrawal lever ball pin and washer from front cover.
15. Remove front cover mounting bolts. Then remove front cover and front cover gasket from transmission case.





16. Remove front cover oil seal from front cover using a flat-bladed screwdriver.

CAUTION: Be careful not to damage front cover mating surface.





17. Remove baffle plate mounting nut from transmission case.





18. Remove snap ring from main drive gear bearing using snap ring pliers.





19. Carefully tap on transmission case to separate it from adapter plate using a soft hummer.





20. Remove counter front bearing from transmission case.
21. Remove oil gutter from transmission case.

Shift Control Components





1. Install adapter setting plate to adapter plate, and then secure adapter setting plate in a vise.
Tool number : ST224490000 ( - )





2. Remove baffle plate mounting bolts and baffle plate from adapter plate.

NOTE: Mounting bolts are installed both from the front side and the reverse side of adapter plate.





3. Remove magnet from adapter plate.
4. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove striking lever and striking rod.





5. Remove check ball plugs, check ball springs and check balls from adapter plate.





6. Remove 3rd/4th control lever mounting bolts and 3rd/4th control lever from adapter plate.





7. Remove shifter cap from 3rd/4th control lever.
8. Remove check ball plug, check ball spring and check ball from adapter plate.





9. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 3rd/4th fork rod bracket and 3rd/4th fork rod.





10. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 3rd/4th fork rod (reversal side) and 3rd/4th shift fork.





11. Remove check balls and interlock pin from adapter plate.





12. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 1st/2nd fork rod and 1st/2nd shift fork.





13. Remove interlock plunger and interlock pin from adapter plate.





14. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove reverse fork rod and reverse shift fork.





15. Remove check balls from adapter plate.





16. Remove 5th/6th control lever mounting bolts, and 5th/6th control lever from adapter plate.





17. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 5th/6th fork rod and 5th/6th fork rod bracket.





18. Drive out retaining pin using a pin punch [6 mm (0.24 inch) dia.], and remove 5th/6th fork rod (reversal side) and 5th/6th shift fork.

Gear Components





^ Before disassembly, measure end play for each position. If the end play is outside the specifications, disassemble and inspect.
^ Main drive gear
End play: 0 - 0.1 mm (0 - 0.004 inch)





^ Main shaft rear side
End play: 0 - 0.1 mm (0 - 0.004 inch)





^ Counter gear
End play: 0 - 0.1 mm (0 - 0.004 inch)





1. After removing snap ring, remove reverse synchronizer assembly and reverse main gear from main shaft using a puller.
Tool number: Commercial service tool
2. Remove reverse main needle bearing from main shaft.





3. Remove main shaft bearing retainer mounting bolts and main shaft bearing retainers from adapter plate.





4. After removing snap ring, remove reverse counter gear and counter rear bearing spacer using a puller.
Tool number: Commercial service tool





5. Remove snap ring from main shaft bearing.





6. Remove main shaft assembly and counter shaft assembly together from adapter plate.





7. Remove counter rear bearing from adapter plate.
8. Remove main drive gear, main pilot bearing, pilot bearing spacer and 5th baulk ring from main shaft.





9. Remove snap ring from main drive gear using snap ring pliers.





10. Set a puller on main drive gear bearing, and remove main drive gear bearing from main drive gear using a press.
Tool number : Commercial service tool





11. Set a puller on 4th main gear, and remove reverse main gear bushing, main shaft bearing and 4th main gear from main shaft using a press.
Tool number : Commercial service tool





12. Remove 3rd/4th main spacer from main shaft.
13. Set a puller on 1st main gear, and remove 3rd main gear and 1st main gear from main shaft using a press.
Tool number : Commercial service tool

CAUTION: Be careful not to damage baulk ring.

14. Remove 1st needle bearing from main shaft.





15. Set a puller on 2nd main gear, and remove 1st/2nd synchronizer assembly and 2nd main gear from main shaft using a press.
Tool number : Commercial service tool

CAUTION: Be aware that when using the press, if the main shaft gear positioner catches on the V-block, etc., the main shaft could be damaged.

16. Remove 2nd needle bearing from the main shaft.





17. Remove snap ring, then set a puller on 6th main gear, and remove 5th/6th synchronizer assembly, 6th baulk ring and 6th main gear from main shaft using a press.
Tool number : Commercial service tool
18. Remove 6th needle bearing from main shaft.





19. Set a puller on 3rd counter gear, and remove counter rear bearing inner race, 4th counter gear thrust washer, 4th counter gear, 4th inner baulk ring, 4th synchronizer cone, 4th outer baulk ring, 4th needle bearing, 4th gear bushing, 3rd/4th synchronizer assembly, 3rd outer baulk ring, 3rd synchronizer cone, 3rd inner baulk ring and 3rd counter gear from counter shaft using a press.
Tool number : Commercial service tool
20. Remove 3rd needle bearing from counter shaft.





21. Set a puller on 3rd gear bushing, and remove 3rd gear bushing from counter shaft using a press.
Tool number : Commercial service tool

INSPECTION AFTER DISASSEMBLY
Shift Control Components





If the contact surfaces of striking lever, fork rod, shift fork, etc. have excessive wear, abrasion, bend, or any other damage, replace the component.

Gear and Shaft Components








If the contact surfaces of each gear, main shaft, main drive gear and counter shaft, etc. have damage, peeling, abrasion, dent, bend, or any other damage, replace the component.

Synchronizer Components





^ If the contact surfaces of coupling sleeves, synchronizer hubs and shifting inserts have damage or abrasion, replace the component.
^ Each set of coupling sleeve and synchronizer hub should move smoothly.





^ If the cam surfaces of baulk rings or contact surfaces of shifting inserts have damage or excessive wear, replace with a new one.
^ If spread springs are damaged, replace with a new one.

Single-Cone Synchronizer (5th and 6th)





^ Push baulk ring on cone and measure baulk ring back surface clearance at two locations or more on opposite sides. Find the average value, and replace baulk ring if it is below the limit value.
Clearance Standard: 0.7 - 1.25 mm (0.028 - 0.049 inch)
Limit value: 0.5 mm (0.02 inch) or less





NOTE: 5th and 6th baulk rings have three spaces that two gear teeth are missing as shown in the figure.

Double Cone Synchronizer (1st, 3rd and 4th)





Follow the instructions and inspect the clearances of outer baulk ring, synchronizer cone, inner baulk ring for 1st, 3rd and 4th gears.

NOTE: Clearances A and B of the outer baulk ring, synchronizer cone and inner baulk ring are controlled as a set. If the clearance is below the limit value, replace them as a set.





1. Measure clearance A at 2 or more points diagonally opposite, and calculate mean value using a dial indicator.
Clearance A
Standard: 0.5 - 0.7 mm (0.02 - 0.028 inch)
Limit value: 0.3 mm (0.012 inch) or less
Tool number: ST30031000 (J-22912-01)





2. Measure clearance B at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance B
Standard 1st: 1.0 - 1.5 mm (0.039 - 0.059 inch)
3rd and 4th: 0.85 - 1.35 mm (0.033 - 0.053 inch)
Limit value: 0.7 mm (0.028 inch) or less





NOTE: 1st and 4th baulk rings have three spaces that one gear tooth is missing as shown in the figure.

Triple-Cone synchronizer (2nd)





Follow the instructions and inspect the clearances of 2nd outer baulk ring, 2nd synchronizer cone and 2nd inner baulk ring.

NOTE: Clearances A, B and C of 2nd outer baulk ring, 2nd synchronizer cone and 2nd inner baulk ring are controlled as a set. If the clearance is below the limit value, replace them as a set.





1. Push 2nd outer baulk ring on 2nd main gear taper cone. Measure clearance A at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance A
Standard value : 0.6 - 1.3 mm (0.024- 0.051 inch)
Limit value : 0.3 mm (0.012 inch) or less





2. Measure clearance B at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance B
Standard value : 0.85 1.35 mm (0.033 0.053 inch)
Limit value : 0.7 mm (0.028 inch) or less





3. Push 2nd outer baulk ring on 2nd main gear taper cone. Measure clearance C at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance C
Standard value : 0.7 - 1.25 mm (0.028 - 0.049 inch)
Limit value : 0.3 mm (0.012 inch) or less





NOTE: 2nd baulk ring has three spaces that the gear teeth are missing as shown in the figure.

Reverse Synchronizer





^ Push baulk ring on cone and measure baulk ring back surface clearance at two locations or more on opposite sides. Find the average value, and replace baulk ring if it is below the limit value.
Clearance
Standard : 0.75 - 1.2 mm (0.03 - 0.047 inch)
Limit value : 0.5 mm (0.02 inch) or less





NOTE: Reverse baulk ring has three spaces that two gear teeth are missing, and each space has groove for identification as shown in the figure.

Bearing





If the bearings do not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with a new one.