Input Shaft Assembly

DISASSEMBLY





1. INSPECT 3RD AND 4TH GEARS THRUST CLEARANCE
Using a feeler gauge, measure the clearance.
Standard clearance:
3rd gear: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
4th gear: 0.20 - 0.45 mm (0.0079 - 0.0177 inch)
Maximum clearance:
3rd gear: 0.30 mm (0.0118 inch)
4th gear: 0.50 mm (0.0197 inch)





2. INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCES
Using a dial indicator, measure the radial clearance between the gear and shaft.
Standard clearance: 0.009 - 0.053 mm (0.0004 - 0.0021 inch)
Maximum clearance: 0.070 mm (0.0028 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.





4. REMOVE REAR BEARING, 4TH GEAR, NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT
a. Using SST and a press, remove the 4th gear and rear bearing.
SST 09950-00020
b. Remove the needle roller bearings, spacer and synchronizer ring.
5. REMOVE SNAP RING
Using a snap ring expander, remove the snap ring.





6. REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR SYNCHRONIZER RING AND NEEDLE ROLLER BEARING
Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.
SST 09950-00020

NOTICE: Be careful not to mistake the 3rd gear synchronizer ring for the 4th gear synchronizer ring.





7. REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND SPRING FROM NO.2 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.2 clutch hub.

INSPECTION
1. INSPECT SYNCHRONIZER RING
a. Check for wear or damage.





b. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

c. Check again the braking effect of the synchronizer ring.





d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 inch)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.





2. INSPECT NO.2 SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace shift fork or hub sleeve.
3. INSPECT INPUT SHAFT
a. Check the input shaft for wear or damage.





b. Using a micrometer, measure the outer diameter of the in put shaft journal surface.
Minimum outer diameter:
Part A: 26.970 mm (1.0618 inch)
Part B: 32.470 mm (1.2783 inch)
Part C: 33.090 mm (1.3028 inch)
Part D: 29.970 mm (1.1799 inch)
If the outer diameter is less than the minimum, replace the input shaft.





c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 inch)
If the runout exceeds the maximum, replace the input shaft.

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.





1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

NOTICE: Position the key springs so that their end gaps are not aligned.

2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply gear oil to the needle roller bearings.





b. Place the synchronizer ring (for the 3rd gear) on the gear and align the ring slots with the shifting keys.

NOTICE: Do not install the synchronizer ring for 4th gear.





c. Using a press, install the 3rd gear and No.2 hub sleeve.








3. INSTALL SNAP RING
a. Select a snap ring that allows the minimum axial play.
b. Using a snap ring expander, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARING, SPACER, 4TH GEAR AND REAR BALL BEARING





a. Apply gear oil to the needle roller bearings.
b. Install the spacer and needle roller bearings.





c. Place the synchronizer ring on the gear.

HINT: Align the ring slots with the shifting keys and the ring projections with the hub slots.





d. Using SST and a press, install the rear ball bearing.
SST 09608-00071








6. INSTALL SNAP RING
a. Select a snap ring that allows the minimum axial play.
b. Using a screwdriver and hammer, tap in the snap ring.
7. INSPECT 4TH GEAR THRUST CLEARANCE