Inspection After Disassembly
INSPECTION AFTER DISASSEMBLYShift Control Components
If the contact surfaces of striking lever, fork rod, shift fork, etc. have excessive wear, abrasion, bend, or any other damage, replace the component.
Gear and Shaft Components
If the contact surfaces of each gear, main shaft, main drive gear and counter shaft, etc. have damage, peeling, abrasion, dent, bend, or any other damage, replace the component.
Synchronizer Components
^ If the contact surfaces of coupling sleeves, synchronizer hubs and shifting inserts have damage or abrasion, replace the component.
^ Each set of coupling sleeve and synchronizer hub should move smoothly.
^ If the cam surfaces of baulk rings or contact surfaces of shifting inserts have damage or excessive wear, replace with a new one.
^ If spread springs are damaged, replace with a new one.
Single-Cone Synchronizer (5th and 6th)
^ Push baulk ring on cone and measure baulk ring back surface clearance at two locations or more on opposite sides. Find the average value, and replace baulk ring if it is below the limit value.
Clearance
Standard : 0.7 - 1.25 mm (0.028 - 0.049 inch)
Limit value : 0.5 mm (0.02 inch) or less
NOTE:
^ 5th and 6th baulk rings have three spaces that two gear teeth are missing as shown in the figure.
Double-Cone Synchronizer (1st, 3rd and 4th)
Follow the instructions below and inspect the clearances of outer baulk ring, synchronizer cone, inner baulk ring for 1st, 3rd and 4th gears.
NOTE: Clearances "A" and "B" of the outer baulk ring, synchronizer cone and inner baulk ring are controlled as a set. If the clearance is below the limit value, replace them as a set.
1. Measure clearance "A" at 2 or more points diagonally opposite, and calculate mean value using a dial indicator.
Clearance "A"
Standard : 0.5 - 0.7 mm (0.02 - 0.028 inch)
Limit value : 0.3 mm (0.012 inch) or less
Tool number : ST30031000 (J22912 - 01)
2. Measure clearance "B" at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance "B"
Standard 1st : 1.0 - 1.5 mm (0.039 - 0.059 inch)
3rd and 4th : 0.85 - 1.35 mm (0.033 - 0.053 inch)
Limit value : 0.7 mm (0.028 inch) or less
NOTE: 1st and 4th baulk rings have three spaces that one gear tooth is missing as shown in the figure.
Triple-cone synchronizer (2nd)
Follow the instructions below and inspect the clearances of 2nd outer baulk ring, 2nd synchronizer cone and 2nd inner baulk ring.
NOTE: Clearances "A", "B" and "C" of 2nd outer baulk ring, 2nd synchronizer cone and 2nd inner baulk ring are controlled as a set. If the clearance is below the limit value, replace them as a set.
1. Push 2nd outer baulk ring on 2nd main gear taper cone. Measure clearance "A" at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance "A"
Standard value : 0.6 - 1.3 mm (0.024 - 0.051 inch)
Limit value : 0.3 mm (0.012 inch) or less
2. Measure clearance "B" at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance "B"
Standard value : 0.85 - 1.35 mm (0.033 - 0.053 inch)
Limit value : 0.7 mm (0.028 inch) or less
3. Push 2nd outer baulk ring on 2nd main gear taper cone. Measure clearance "C" at 2 or more points diagonally opposite, and calculate mean value using a feeler gauge.
Clearance "C"
Standard value : 0.7 - 1.25 mm (0.028 - 0.049 inch)
Limit value : 0.3 mm (0.012 inch) or less
NOTE: 2nd baulk ring has three spaces that the gear teeth are missing as shown in the figure.
Reverse Synchronizer
Push baulk ring on cone and measure baulk ring back surface clearance at two locations or more on opposite sides. Find the average value, and replace baulk ring if it is below the limit value.
Clearance
Standard : 0.75 - 1.2 mm (0.03 - 0.047 inch)
Limit value : 0.5 mm (0.02 inch) or less
NOTE: Reverse baulk ring has three spaces that two gear teeth are missing, and each space has groove for identification as shown in the figure.
Bearing
If the bearings do not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with a new one.