Inspection of Components

1. INSPECT SYNCHRONIZER RING NO.3 FOR FIFTH GEAR
a. Check for wear or damage.
b. Turn the ring and push it in to check the braking action.




c. Measure the clearance between the synchronizer ring back and the gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the limit, replace the synchronizer ring.




2. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the limit, replace the shift fork or hub sleeve.




3. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL
a. Using SST, pull out the bearing.
SST 09308-00010




b. Using a screwdriver, remove the oil seal.




c. Using SST, drive in a new oil seal.
SST 09608-20012 (09608-00080, 09608-03020)

Drive in depth: 1.0 2.0 mm (0.039 0.079 in.)

d. Coat the lip of the oil seal with MP grease.




e. Using SST, press in a new bearing.
SST 09310-35010




4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER
a. Remove the bolt and bearing lock plate.




b. Using SST, pull out the bearing.
SST 09308-00010
c. Remove the output shaft cover.




d. Install the output shaft cover.

HINT: Install the output shaft cover projection into the case side groove.




e. Using SST, press in a new bearing.
SST 09310-35010




f. Install the bearing lock plate and torque the bolt.

Torque: 185 kg-cm (13 ft-lb, 18 N-m)




5. IF NECESSARY, REPLACE CONTROL SHAFT COVER OIL SEAL
a. Using a screwdriver and hammer, remove the oil seal.




b. Using a 17 mm socket and extension bar, drive in a new oil seal.

Drive in depth: 9.7 - 10.3 mm (0.382 - 0.406 in.)

c. Coat the lip of the oil seal with MP grease.




6. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL
a. Using SST, pull out the oil seal.
SST 09921-00010




b. Using SST, drive in a new oil seal.
SST 09201-60011

Drive in depth: 19 mm (0.75 in.)




7. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
a. Using SST, remove the screw plug.
SST 09313-30021
b. Using a pin punch and hammer, drive out the slotted spring pin.




c. Replace the reverse restrict pin.




d. Using a pin punch and hammer, drive in the slotted spring pin.
e. Apply liquid sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using SST, install the screw plug.
SST 09313-30021

Torque: 130 kg-cm (9 ft-lb, 13 N-m)