PRIMARY SHAFT COMPONENTS INSPECTION

4th Gear, 3rd 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.

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 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}

3rd/4th Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.

• 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 keys for damage, wear, and cracks.

• If there is any malfunction, replace parts if 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: 0.10-0.40 mm {0.004-0.015 in}

Maximum: 0.90 mm {0.035 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.

0.050 mm {0.0020 in}

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

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

3rd and 4th gear oil clearance (mm {in})

Gear	Shaft (Outer dia.)	Gear (Inner dia.)	Clearance
3rd	35.945-35.970 {1.415-1.416}	36.000-36.025 {1.417-1.418}	0.030-0.080 {0.001-0.003}
4th	30.945-30.970 {1.218-1.219}	31.000-31.025 {1.220-1.221}