SECONDARY SHAFT COMPONENTS INSPECTION

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Gears 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 side of gear circumferentially using a feeler gauge.

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

  1st and 2nd synchronizer ring clearance

  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 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 fork.

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

  1st/2nd clutch hub sleeve and shift fork clearance

  Standard: 0.10—0.45 mm {0.004—0.017 in}
  Maximum: 0.95 mm {0.037 in}

Secondary Shaft Gear Inspection

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

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

2. Inspect the splines for damage and wear.

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

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

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

4. Inspect the oil passage for clogging.

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

5. Measure the shaft gear runout.

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

  Secondary shaft gear maximum runout

  0.015 mm {0.0006 in}

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

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

1st and 2nd gear oil clearance (mm {in})

Gear | Shaft (outer dia.) | Gear (inner dia.) | Clearance
--- | --- | --- | ---
1st | 39.445—39.470 {1.5530—1.5539} | 39.500—39.525 {1.5552—1.5561} | 0.030—0.080 {0.0012—0.0031}
2nd | 34.945—34.965 {1.3758—1.3765} | 35.015—35.035 {1.3786—1.3793} | 0.050—0.090 {0.0020—0.0035}