Output Shaft Assembly

DISASSEMBLY

1. INSPECT 1ST AND 2ND GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 - 0.29 mm (0.0039 - 0.0114 inch)
2nd gear: 0.20 - 0.44 mm (0.0079 - 0.0173 inch)
Maximum clearance:
1st gear: 0.35 mm (0.0138 inch)
2nd gear: 0.50 mm (0.0197 inch)

2. INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE
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 REAR BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER
a. Using SST and a press, remove the rear ball bearing and 4th driven gear.
SST 09950-00020
b. Remove the output gear spacer and ball.

4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING AND SYNCHRONIZER RING
a. Shift the No.1 hub sleeve into the 1st gear.
b. Using SST and a press, remove the 3rd driven gear and 2nd gear.
SST 09950-00020
c. Remove the needle roller bearing and synchronizer rings.

5. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND LOCKING BALL
a. Using a press, remove the No. 1 hub sleeve, 1st gear and synchronizer ring.
b. Remove the needle roller bearing and locking ball.
c. Using a screwdriver and hammer, drive out the thrust washer.

6. REMOVE NO.1 HUB SLEEVE, 3 SHIFTING KEYS AND SPRINGS FROM NO.1 CLUTCH HUB

INSPECTION
1. INSPECT 1ST GEAR 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 the 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 2ND GEAR SYNCHRONIZER RING
a. Check for wear or damage.

c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.7 mm (0.028 inch)
If the clearance is less than the minimum, replace the synchronizer ring.

3. INSPECT 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 the shift fork or hub sleeve.
4. INSPECT OUTPUT SHAFT

a. Using a micrometer, measure the outer diameter of the output shaft journal surface.
Minimum outer diameter:
Part A: 31.970 mm (1.2587 inch)
Part B: 37.970 mm (1.4949 inch)
Part C: 31.990 mm (1.2594 inch)
If the outer diameter is less than the minimum, replace the out put shaft.

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

REASSEMBLY

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

1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
a. Install the 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.

HINT: Position the identification groove of the hub sleeve to the front of the transmission.

2. INSTALL THRUST WASHER, 1ST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT

a. Using SST and a press, install the thrust washer.
SST 09316-60011 (09316-00041)
b. Apply gear oil to the needle roller bearing.

c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.

d. Using a press, install the 1st gear and No.1 hub sleeve.
3. INSPECT 1ST GEAR THRUST CLEARANCE
4. INSTALL SYNCHRONIZER RING, 2ND GEAR, NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
a. Install the ball.

b. Fit the 2nd gear bushing groove securely over the ball when installing the 2nd gear bushing on the shaft.
c. Place the synchronizer rings on the 2nd gear.
d. Apply gear oil to the needle roller bearing and install it.
e. Install the 2nd gear.

NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring.

f. Using SST and a press, install the 3rd driven gear.
SST 09316-60011 (09316-00011)
5. INSPECT 2ND GEAR THRUST CLEARANCE

6. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND RADIAL BALL BEARING
a. Install the outer gear spacer.
b. Using a press, install the 4th driven gear and bearing.

7. INSTALL REAR BEARING
Using SST and a press, install the rear bearing.