Input Shaft
INPUT SHAFT:
DISASSEMBLY
1. MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Maximum clearance:
3rd gear: 0.35 mm (0.0138 inch)
4th gear: 0.57 mm (0.0224 inch)
2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
Maximum clearance:
3rd gear: 0.053 mm (0.0021 inch)
4th gear: 0.051 mm (0.0020 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 AND 4TH GEAR
Using SST and a press, remove the rear bearing and 4th gear.
SST 09950-00020
5. REMOVE 2 NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING
6. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
7. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, SYNCHRONIZER RING AND 3RD GEAR
Using a press, remove the No. 2 hub sleeve assembly, synchronizer ring and 3rd gear.
8. REMOVE 2 NEEDLE ROLLER BEARINGS
9. DISASSEMBLY NO. 2 HUB SLEEVE ASSEMBLY
a. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
b. Remove the 3 shifting keys and springs from the No. 2 clutch hub.
10. REMOVE INPUT SHAFT FRONT BEARING INNER RACE
Using a screwdriver and hammer, remove the input shaft front bearing inner race.
INSPECTION
1. INSPECT 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 spline end.
Minimum clearance:
3rd gear: 0.65 mm (0.0256 inch)
4th gear: 0.75 mm (0.0295 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. MEASURE NO. 2 SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 0.69 mm (0.0272 inch)
If the clearance exceeds the maximum, replace the 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 input shaft journal surface.
Minimum outer diameter:
Part A: 27.957 mm (1.1007 inch)
Part B: 35.984 mm (1.4167 inch)
c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.03 mm (0.0012 inch)
REASSEMBLY
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.
1. INSTALL INPUT SHAFT FRONT BEARING INNER RACE
Using SST and a press, install a new input shaft front bearing inner race.
SST 09608-00071
2. INSTALL NO. 2 CLUTCH HUB INTO NO. 2 HUB SLEEVE
a. Install the 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.
NOTICE: Assembly the hub sleeve and clutch hub in the direction shown in the illustration.
3. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO. 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearing and install it.
b. Install the 3rd gear.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Using SST and a press, install the No. 2 hub sleeve assembly.
SST 0950-35010
4. 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.
5. MEASURE 3RD GEAR THRUST CLEARANCE
6. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND REAR BEARING
a. Install the spacer.
b. Apply MP grease to the 2 needle roller bearings and install it.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Install the 4th gear.
e. Using SST and a press, install the rear bearing.
SST 09309-36010
7. 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.
8. MEASURE 4TH GEAR THRUST CLEARANCE