PRIMARY SHAFT COMPONENTS INSPECTION

4th Gear, 3rd Gear Inspection

1. Inspect the synchronizer cones for wear.

• If there is any malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

• If there is any malfunction, replace parts as necessary.

3. Inspect the synchronizer ring matching teeth for damage and wear.

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

4th Synchronizer Ring, 3rd Synchronizer Ring Inspection

1. Inspect the synchronizer ring teeth for damage, wear, and cracks.

• If there is any malfunction, replace parts as necessary.

2. Inspect the tapered surface for wear and cracks.

• If there is any malfunction, replace parts as necessary.

3. Measure the clearance between the synchronizer ring and the flank surface of the gear.

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

Note

• Set the synchronizer ring squarely in the gear and measure around the circumference.

Standard clearance

1.12-1.88 mm {0.044-0.074 in}

Minimum clearance

0.80 mm {0.031 in}

3rd/4th Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.

• If there is any malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

• If there is any malfunction, replace parts as necessary.

3. Inspect the synchronizer keys for damage, wear, and cracks.

• If there is any malfunction, replace parts as necessary.

4. Measure the clearance between the hub sleeve and shift forks.

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

Standard clearance

0.20-0.50 mm {0.008-0.020 in}

Maximum clearance

1.00 mm {0.039 in}

Primary Shaft Gear Inspection

1. Inspect the gear contact surface for damage and wear.

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

2. Inspect the splines for damage and wear.

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

3. Inspect the gear teeth for damage, wear, and cracks.

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

4. Inspect the oil passage for clogging.

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

5. Measure the shaft gear runout.

• If it exceeds the maximum specification, replace the primary shaft.

Maximum runout

0.050 mm {0.0020 in}

6. Measure the clearance between the shaft gears and the gears.

• If not within the specification, replace parts as necessary.