Part 3
UNIT ASSEMBLYGear Shift Lever Case
1. Wash and inspect each part and replace if necessary. Also check item as described below and correct whatever necessary carefully by using reamer, oilstone and the like, wash it thoroughly and reassemble it.
Item to be checked is;
- Shift shaft should go into case smoothly.
2. Insert shift shaft as shown while making sure that inner parts are in proper direction.
NOTE:
^ Cut off in shift shaft should face downward when shift shaft is installed.
^ Shift lever should be installed at the same time.
3. Drive in spring pins for gear shift lever and shift arm.
NOTE: When driving in spring pins, position their slits 180° ± 30° apart.
Special Tool
(A): 09925-78210
4. Apply sealant to new case plug and drive it into lever case.
"A": Sealant 99000-31110
5. Clean mating surface of gear shift lever case and case plate, and then apply sealant evenly to surface of gear shift lever case.
"A": Sealant 99000-31110
6. Tighten screws to specified torque.
Tightening Torque
(b): 6 Nm (0.6 kg-m, 4.5 ft. lbs.)
7. Install gearshift lever case to transmission without using sealant for functional check.
8. Install shift control lever and check to make sure that it shifts smoothly according to shift pattern as shown in figure.
NOTE:
^ Apply thread lock cement to control lever locating bolts when retightening.
^ Be sure to apply sealant to mating surface of gear shift lever for its final installation.
"C": Cement 99000-32020
Tightening Torque
(a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
Input Shaft Ass'y
1. Bring bearing so that its groove for circlip is in the front and press-fit with special tool and press.
Special Tool
(A): 09940-51710
2. Select circlip that will make thrust clearance of bearing 0.1 mm (0.0039 inch) or less and install it.
3. Apply grease to bearing roller and install it to input shaft.
Grease: 99000-25010
Main Shaft Ass'y
NOTE:
^ Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear.
^ Use new circlips on shaft for installation. Don't reuse circlips.
1. Fit sleeve to high speed hub, place 3 synchronizer keys and set synchronizer springs as shown.
Neither sleeve nor key has specific installing direction.
2. Install synchronizer ring by matching its key slots to keys as shown.
3. Insert 3rd gear, needle bearing and high speed sleeve/hub ass'y with synchronizer ring to main shaft.
4. Press-fit high speed sleeve/hub ass'y with special tool and press.
Special Tool
(A): 09940-53111
5. Select circlip that will make thrust clearance of clutch hub 0.1 mm (0.0039 inch) or less and install it.
Special Tool
(B): 09900-06107
6. After installing circlip, check that 3rd gear turns lightly.
7. Check 3rd gear thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace.
Standard: 0.10 - 0.25 mm (0.004 - 0.009 inch)
8. Fit sleeve to low speed hub, place 3 synchronizer keys in it and then set synchronizer springs. Refer to figure for proper installing direction, sleeve and springs.
9. Install synchronizer ring by matching its key slots to keys as shown.
10. Insert 2nd gear, needle bearing and low speed sleeve/hub ass'y with synchronizer ring.
11. Press-fit low speed sleeve/hub ass'y with special tool and press.
Special Tool
(A): 09940-53111
12. Check 2nd gear thrust clearance referring to "Main Shaft Ass'y" of "INSPECTION".
13. Apply grease to ball and set it to main shaft.
14. Install synchronizer ring.
15. Install needle bearing, low gear and needle bush to main shaft.
NOTE:
^ Check the cut in needle bush and ball are engaged.
^ After installation, check the synchronizer ring moves in circurnferencial direction.
16. Press-fit main shaft bearing and 5th gear with special tools and press.
NOTE: Bring bearing so that its groove for circlip is in the rear.
Special Tool
(C): 09940-51710 or 09925-18010
17. Select circlip that will make its thrust clearance 0.1 mm (0.0039 inch) or less and install it.
18. Check low gear clearance referring to "Main Shaft Ass'y" of "INSPECTION".
Counter Shaft & Reverse Idle Gear
1. Fit sleeve to counter shaft 5th gear, place 3 synchronizer keys in it and then set synchronizer springs. Refer to figure for proper installing direction of gear, sleeve and springs. Also, note that key has specific installing direction.
2. Set inner race to counter shaft front bearing and press-fit bearing with press and special tool.
NOTE: When installing bearing, bring it so that its groove for circlip is in the front.
Special Tool
(A): 09940-54950
3. Select circlip that will make its thrust clearance 0.1 mm (0.0039 inch) or less and install it.
Special Tool
(B): 09900-06107
Input Shaft Bearing Retainer and Oil Seal
Install new oil seal to bearing retainer by using special tool as shown.
Apply grease to oil seal lip.
Grease "A": 99000-25010
Special Tool
(A): 09913-75821
(B): 09924-84510-004
"a": 12.2 - 13.2 mm (0.49 - 0.51 inch)
Transmission Rear Case
1. Check that interlock cam comp. moves smoothly in both turning direction and sliding direction.
2. Insert interlock cam comp. to rear case.
3. Set interlock cam comp. as shown and drive pin by using special tool.
Special Tool
(A): 09922-85811
4. Apply thread lock cement to thread of interlock cam plug and tighten it to specification.
"A": Cement 99000-32020
Tightening Torque
(a): 19 Nm (1.9 kg-m, 14.0 ft. lbs.)
5. Install oil seal to rear case so that end surface of oil seal becomes flush with that case. Apply grease to oil seal lip.
Grease: 99000-25010
Special Tool
(B): 09913-77510
6. Install counter shaft gutter.
Transmission Intermediate Case & Front Case (Location of Knock and Plug)
- Install knock pin and plug (sealant applied) to front case as shown.
"A": Sealant 99000-31110
- Install knock pin/ring pin as shown.