SECONDARY SHAFT COMPONENTS INSPECTION

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.

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

Clearance

Standard: 1.50 mm {0.059 in}

Maximum: 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.

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

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.

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

Maximum runout

0.015 mm {0.0006 in}

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

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

mm {in}

Gear	Shaft (outer dia.)	Gear (inner dia.)	Clearance
1st	39.445-39.470 {1.553-1.554}	39.500-39.525 {1.555-1.556}	0.030-0.080 {0.002-0.003}
2nd	34.945-34.965 {1.376-1.377}	35.015-35.035 {1.378-1.379}	0.05-0.09 {0.002-0.003}