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PRIMARY SHAFT COMPONENTS INSPECTION

B3E051517201103

## 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.

Gear | Shaft (Outer dia.) | Gear (Inner dia.) | Clearance
--- | --- | --- | ---
3rd | 35.15-35.17 {1.384-1.385} | 35.21-35.23 {1.386-1.387} | 0.040-0.080 {0.0016-0.0031}
4th | 31.95-31.97 {1.258-1.259} | 32.01-31.03 {1.260-1.261}