SECONDARY SHAFT COMPONENT INSPECTION

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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. For the X and Y directions as shown in the figure, measure the inner diameter of the gear using a cylinder gauge.

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Inner diameter of gear

Measurement location	Specification (mm {in})	Maximum (mm {in})
Secondary 1st gear	41.510 {1.6343}	41.520 {1.6346}
Secondary 2nd gear	37.010 {1.4571}	37.020 {1.4575}

• If it exceeds the maximum, replace the gear.

Secondary Shaft Inspection

1. Inspect the spline for damage and wear.

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

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

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

3. Measure the runout of the secondary shaft.

(1) Set the secondary shaft on V-blocks so that the V-blocks support the secondary shaft journal as shown in the figure.

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(2) Measure the runout of the position shown in the figure for the secondary shaft using a dial gauge.

Runout of secondary shaft

Maximum: 0.050 mm {0.0020 in}

• If it exceeds the maximum, replace the secondary shaft.

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

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Outer diameter of secondary shaft

Measurement location	Specification (mm {in})	Minimum (mm {in})
A: Secondary 1st gear assembly part	41.470 {1.6327}	41.460 {1.6323}
B: Secondary 2nd gear assembly part	36.970 {1.4555}	36.960 {1.4551}

• If it is less than the minimum, replace the secondary 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 (1GR)	0.990 {0.0390}	0.500 {0.0197}
Synchronizer ring (2GR)	0.990 {0.0390}	0.500 {0.0197}

• 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

Specification: 0.225 mm {0.0089 in}

Maximum: 0.400 mm {0.0157 in}

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