Output Shaft

DISASSEMBLY





1. INSPECT 1ST AND 2ND GEARS THRUST CLEARANCES
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 - 0.40 mm (0.0039 - 0.0157 inch)
2nd gear: 0.10 - 0.45 mm (0.0039 - 0.0177 inch)
Maximum clearance: 1st gear: 0.45 mm (0.0177 inch)
2nd gear: 0.50 mm (0.0197 inch)





2. INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCES
Using a dial indicator, measure the radial clearance between the gear and shaft.
Standard clearance: 0.015 - 0.058 mm (0.0006 - 0.0023 inch)
Maximum clearance: 0.070 mm (0.0028 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing and shaft.





3. REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
a. Using SST and a press, remove the ball bearing and 4th driven gear.
SST 09950-00020
b. Remove the output spacer.
4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND SPACER





a. Shift the No.1 hub sleeve into the 1st gear.





b. Using SST and a press, remove the 3rd driven gear.
SST 09950-00020
c. Remove the 2nd gear, needle roller bearing, synchronizer ring and spacer.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.





6. REMOVE REVERSE GEAR ASSEMBLY, 1ST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND BALL
a. Using a press, remove the No.1 hub sleeve assembly, 1st gear and synchronizer ring.
b. Remove the needle roller bearing, thrust washer and ball.





7. REMOVE REVERSE GEAR, SHIFTING KEY AND SPRING FROM NO.1 CLUTCH HUB
Remove the 3 shifting keys and springs from the No.1 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 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.
3. INSPECT OUTPUT SHAFT
a. Check the output shaft for wear or damage.





b. Using a micrometer, measure the outer diameter of the output shaft journal surface.
Minimum outer diameter:
Part A: 32.970 mm (1.2980 inch)
Part B: 37.970 mm (1.4949 inch)
Part C: 31.970 mm (1.2587 inch)
If the outer diameter is less than the minimum, replace the output 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 output shaft.

REASSEMBLY

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





1. INSTALL NO.1 CLUTCH HUB INTO REVERSE GEAR
a. Install the 3 springs and shifting keys to the No.1 clutch hub.
b. Install the No.1 clutch hub to the reverse gear.





2. INSTALL BALL, THRUST WASHER, 1ST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND REVERSE GEAR ASSEMBLY TO OUTPUT SHAFT
a. Install the ball to the shaft.
b. Fit the thrust washer groove securely over the locking ball and install the washer on the shaft.
c. Apply gear oil to the needle roller bearing.
d. Install the needle roller bearing, 1st gear and synchronizer ring.





e. Place the synchronizer ring on the gear and align the clutch hub grooves with the projections on the synchronizer ring.





f. Using a press, install the 1st gear and reverse gear.








3. 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.
4. INSPECT 1ST GEAR THRUST CLEARANCE





5. INSTALL SYNCHRONIZER RING, SPACER, NEEDLE ROLLER BEARING, 2ND GEAR AND 3RD DRIVEN GEAR
a. Place the synchronizer ring on the gear and align the clutch hub grooves with the projections on the synchronizer ring.
b. Install the spacer.
c. Apply gear oil to the needle roller bearing.
d. Install the needle roller bearing.
e. Install the 2nd gear.





f. Using a press, install the 3rd driven gear.
6. INSPECT 2ND GEAR THRUST CLEARANCE





7. INSTALL OUTPUT GEAR SPACER AND 4TH DRIVEN GEAR
a. Install the output gear spacer.
b. Using a press, install the 4th driven gear.





8. INSTALL REAR BALL BEARING
Using SST and a press, install the rear ball bearing.
SST 09316-60011 (09316-00021)