Inspection After Disassembly
INSPECTION AFTER DISASSEMBLYShift Control
If the contact surface on striking lever, fork rod, shift fork, etc. has excessive wear, abrasion, bend, or any other damage, replace the components.
Gear and Shaft
If the contact surface on each gear, main shaft, main drive gear, and counter shaft, etc. has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.
Synchronizer
^ If the contact surface on coupling sleeve, synchronizer hub, and shifting insert has damage or abrasion, replace the components.
^ Coupling sleeve and synchronizer hub shall move smoothly.
^ If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one.
^ If spread spring is damaged, replace with a new one.
Baulk Ring Clearance
^ Single cone synchronizer (5th and 6th)
- Push baulk ring on the cone and measure baulk ring back surface clearance at two locations or more on opposite sides, find the average value, and replace it if it is outside the limit value.
Clearance
Standard value: 0.70 - 1.35 mm (0.028 - 0.053 inch)
Limit value: 0.5 mm (0.020 inch) or less
^ Double cone synchronizer (4th)
Follow the instructions below and inspect the clearance of the outer baulk ring, synchronizer cone, inner baulk ring.
CAUTION: Clearances "A" and "B" of the outer baulk ring, synchronizer cone, and inner baulk ring are controlled as a set, so if the clearance is outside the limit value, replace the synchronizer assembly.
1. Using a dial indicator, measure clearance A at 2 or more points diagonally opposite, and calculate mean value.
Clearance A
Standard value: 0.50 - 0.70 mm (0.020 - 0.028 inch)
Limit value: 0.3 mm (0.012 inch) or less
2. Using a feeler gauge, measure clearance B at 2 or more points diagonally opposite, and calculate mean value.
Clearance B
Standard value: 0.85 - 1.35 mm (0.033 - 0.053 inch)
Limit value: 0.7 mm (0.028 inch) or less
^ Triple cone synchronizer (1st, 2nd and 3rd)
Check clearance for outer baulk ring, synchronizer cone and inner baulk ring of triple cone synchronizer following the direction.
NOTE: Outer baulk ring, synchronize cone and inner baulk ring, three control "clearance A, B and C" as a three-piece suite. If the value exceeds the limit value, replace them as a three-piece suite.
1. Using feeler gauge put and press baulk ring on gear taper cone, and then measure "clearance A" at more then 2 diagonal points, and calculate the average.
Clearance A
Standard value (1st): 0.65 - 1.25 mm (0.026 - 0.049 inch)
Standard value (2nd, 3rd): 0.60 - 1.30 mm (0.024 - 0.051 inch)
Limit value: 0.3 mm (0.012 inch) or less
2. Using feeler gauge measure "clearance B" at more than 2 diagonal positions, and calculate the average.
Clearance B
Standard value: 0.85 - 1.35 mm (0.033 - 0.053 inch)
Limit value: 0.7 mm (0.028 inch) or less
3. Using feeler gauge put and press baulk ring on gear taper cone, and then measure "clearance C" at more then 2 diagonal points, and calculate the average.
Clearance C
Standard value (1st): 0.80 - 1.2 mm (0.031 - 0.047 inch)
Standard value (2nd, 3rd): 0.75 - 1.25 mm (0.030 - 0.049 inch)
Limit value: 0.3 mm (0.012 inch) or less
^ Reverse synchronizer
Push baulk ring on the cone and measure baulk ring back surface clearance at two locations or more on opposite sides, find the average value, and replace if it is outside the limit value.
Clearance
Standard value: 0.75 - 1.20 mm (0.030 - 0.047 inch)
Limit value: 0.5 mm (0.020 inch) or less
Bearing
If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.