PRIMARY SHAFT COMPONENT INSPECTION

id051500168800


Gear inspection

1.  Inspect the gears for damage, wear, or loss.

•  If there is any malfunction, replace the gear.

2.  Inspect the gears and synchronizer rings for damage and wear on contact surfaces.

•  If there is any malfunction, replace the gear.

3.  Measure the gear circumference in the X and Y directions as shown in the figure using a cylinder gauge.

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Inner diameter of gear

Measurement location

Specification (mm {in})

Maximum (mm {in})
3rd gear
41.510 {1.6343}
41.520 {1.6346}
4th gear
37.010 {1.4571}
37.020 {1.4575}
5th gear
37.010 {1.4571}
37.020 {1.4575}
6th gear
32.810 {1.2917}
32.820 {1.2921}

•  If it exceeds the maximum, replace the gear.


Primary Shaft Inspection

1.  Inspect the spline for damage and wear.

•  If there is any malfunction, replace the primary shaft.

2.  Inspect the gear area for damage, wear, and loss.

•  If there is any malfunction, replace the primary shaft.

3.  Measure the runout of the primary shaft.

(1)  Set the primary shaft on V-blocks so that the V-blocks support the primary shaft journal as shown in the figure.
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(2)  Measure the runout of the position shown in the figure for the primary shaft using a dial gauge.
Primary shaft runout
Maximum: 0.050 mm {0.0020 in}
•  If it exceeds the maximum, replace the primary shaft.

4.  Measure the outer diameter of the primary shaft using the micrometer. Measurement positions total eight and are in the X and Y directions, at four points (A, B, C, and D) as shown in the figure.

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Outer diameter of primary shaft

Measurement location

Specification (mm {in})

Minimum (mm {in})
A: 6th gear assembly part
32.770 {1.2902}
32.760 {1.2898}
B: 5th gear assembly part
36.970 {1.4555}
36.960 {1.4551}
C: 4th gear assembly part
36.970 {1.4555}
36.960 {1.4551}
D: 3rd gear assembly part
41.470 {1.6327}
41.460 {1.6323}

•  If it is less than the minimum, replace the primary shaft.


Synchronizer Ring Inspection

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

•  If there is any malfunction, replace the synchronizer ring.

2.  Inspect the taper surface for wear or loss.

•  If there is any malfunction, replace the synchronizer ring.

3.  While holding the synchronizer ring and gear with your fingers as shown in the figure, measure the clearance of the synchronizer ring and gear side surface around the entire circumference using a thickness gauge.

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Clearance between synchronizer ring and gear

Measurement location

Specification (mm {in})

Minimum (mm {in})
Synchronizer ring (3GR)
1.000 {0.0394}
0.435 {0.0171}
Synchronizer ring (4GR)
1.000 {0.0394}
0.435 {0.0171}
Synchronizer ring (5GR)
1.000 {0.0394}
0.520 {0.0205}
Synchronizer ring (6GR)
1.000 {0.0394}
0.520 {0.0205}

•  If it is less than the minimum, replace the synchronizer ring.


Clutch Hub Component Inspection

1.  Inspect the clutch hub sleeve and clutch hub operation.

•  If there is any malfunction, replace the malfunctioning part.

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

•  If there is any malfunction, replace the malfunctioning part.

3.  While holding the clutch hub sleeve and shift fork together with your hand as shown in the figure, measure the clearance between the shift fork and clutch hub sleeve groove using a thickness gauge.

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Clearance between shift fork and clutch hub sleeve groove

Measurement location

Specification (mm {in})

Maximum (mm {in})
Shift fork (3GR/4GR)
0.225 {0.0089}
0.400 {0.0157}
Shift fork (5GR/6GR)
0.225 {0.0089}
0.400 {0.0157}

•  If it exceeds the maximum, replace the clutch hub sleeve and shift fork as a set.