#
5TH/REVERSE GEAR AND HOUSING PARTS INSPECTION

B3E051501029104

## 5th and Reverse 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.

## 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}

## 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 fork.

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

  Standard clearance
  0.40-0.75 mm {0.016-0.029 in}
  Maximum clearance
  1.25 mm {0.049 in}

## Reverse Idle Gear and Reverse Lever Inspection

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

  • If there is any malfunction, replace the reverse idle gear.

2. Measure the clearance between the reverse idle gear bushing and the reverse lever.

  • If it exceeds the maximum specification, replace as necessary.

  Standard clearance
  0.10-0.32 mm {0.004-0.013 in}
  Maximum clearance
  0.37 mm {0.015 in}

## 5th Gear and Sleeve Inspection

1. Measure the clearance between the 5th gear and the sleeve.

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

  5th gear inner diameter
  34.01-34.03 mm {1.3390-1.3397 in}
  Sleeve outer diameter
  33.94-33.97 mm {1.3363-1.3374 in}
  Standard clearance
  0.04-0.09 mm {0.0016-0.0035 in}