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5TH/6TH GEAR AND HOUSING PARTS INSPECTION

id051500810300

## 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.

5th and 6th gear 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 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.

5th/6th clutch hub sleeve and shift fork clearance

  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