MAINSHAFT AND COUNTERSHAFT PARTS INSPECTION

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Bearing Inspection

1. Inspect for damage and the rotation condition.

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• If there is any malfunction, replace the bearing.

Each Gear, Main Drive Gear Inspection

1. Inspect the following. If there is any malfunction, replace the malfunctioning part.

• Inspect for wear of the synchronizer cone.

• Inspect the teeth of each gear for damage, wear, or loss.

• Inspect the connection part of the hub sleeve for wear or damage.

• Inspect the teeth of the synchronizer ring for damage, wear, or loss.

• Inspect the main drive gear spline for damage, wear, or loss.

Shift Fork (3rd/4th) Inspection

1. Using a thickness gauge, measure the clearance between each shift fork and the clutch hub sleeve groove.

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Clearance between clutch hub sleeve and shift fork

Standard: 0.2—0.3 mm {0.008—0.011 in}

Maximum: 0.5 mm {0.02 in}

• If it exceeds the maximum specification, replace the shift fork and clutch hub sleeve.

Clutch Hub Component (3rd/4th) Inspection

1. Inspect the following. If there is any malfunction, replace the clutch hub component.

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• Inspect the list of operations when the clutch hub sleeve is installed to the hub.

• Inspect the teeth of each gear for damage, wear, or loss.

• Inspect the synchronizer key groove for wear or loss.

Synchronizer ring (3rd/4th/6th) Inspection

1. Inspect the following. If there is any malfunction, replace the synchronizer ring.

• Inspect the teeth of the synchronizer ring for damage, wear, or loss.

• Inspect the taper surface for wear or loss.

2. Measure the clearance of the synchronizer ring and gear side surface around the entire circumference using a thickness gauge.

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Clearance of synchronizer ring (3rd/4th/6th) and gear side surface

Standard: 1.5 mm {0.059 in}

Maximum: 0.8 mm {0.031 in}

• If it exceeds the maximum specification, replace the synchronizer ring.

Countershaft Inspection

1. Inspect the following. If there is any malfunction, replace the countershaft.

• Inspect the teeth of each gear for damage, wear, or loss.

• Inspect the spline for damage, wear, or loss.