5TH/6TH GEAR AND HOUSING PARTS INSPECTION

5th and 6th Gear Inspection

1. Inspect the synchronizer cones for wear.

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

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

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

2. Inspect the tapered surface for wear and cracks.

• If there is any malfunction, replace parts if 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: 1.50 mm {0.059 in}

Minimum: 0.80 mm {0.031 in}

Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.

• If there is malfunction, replace parts if necessary.

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

• If there is malfunction, replace parts if necessary.

3. 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: 0.10-0.36 mm {0.004-0.014 in}

Maximum: 0.86 mm {0.034 in}

Gear and Sleeve Inspection

1. Measure the clearance between the gears and the sleeve.

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

5th and 6th gear oil clearance (mm {in})

Gear	Gear (Inner dia.)	Sleeve (Outer dia.)	Clearance
5th	34.000-34.025 {1.3386-1.3395}	33.945-33.970 {1.3365-1.3373}	0.030-0.080 {0.001-0.003}
6th