Input Shaft Assembly

DISASSEMBLY OF INPUT SHAFT ASSEMBLY







1. INSPECT THIRD AND FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the clearance.

Standard clearance:
3rd gear 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
4th gear 0.20 - 0.45 mm (0.0079 - 0.0177 in.)

Maximum clearance:
3rd gear 0.30 mm (0.0118 in.)
4th gear 0.50 mm (0.0197 in.)




2. INSPECT THIRD AND FOURTH GEAR OIL CLEARANCE
Using dial indicator, measure the oil clearance between the gear and shaft

Standard clearance: 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
Maximum clearance: 0.070 mm (0.0028 in.)

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft




3. REMOVE SNAP RING
Using two screwdriver and a hammer, tap out the snap ring.




4. REMOVE REAR BEARING, FOURTH GEAR, NEEDLE ROLLER BEARINGS, 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, THIRD GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER BEARINGS
Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.
SST 09950-00020

INSPECTION OF INPUT SHAFT COMPONENT PARTS




1. INSPECT SYNCHRONIZER RINGS
a. Check for wear or damage.
b. Turn the ring and push it in to check the bearing action.




c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the minimum, replace the synchronizer ring.




2. INSPECT CLEARANCE OF NO.2 SHIFT FORK AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

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 input shaft journal surface.

Minimum outer diameter:
Part A 26.970 mm (1.0618 in.)
B 32.470 mm (1.2783 in.)
C 33.090 mm (1.3028 in.)
D 29.970 mm (1.1799 in.)

If the outer diameter exceeds the minimum, replace the input shaft.




c. Using a dial indicator, check the shaft runout.

Maximum runout: 0.05 mm (0.0020 in.)

If the runout exceeds the maximum, replace the input shaft.

ASSEMBLY OF INPUT SHAFT ASSEMBLY

HINT: Coat all of the sliding and rotating surface with gear oil before assembly.




1. INSERT 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.

NOTE: Install the key springs positioned so that their end gaps are not in line.




2. INSTALL THIRD GEAR, NEEDLE ROLLER BEARINGS, 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 on the gear and align the ring slots with the shifting keys.




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







3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft




4. INSPECT THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)





5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS, SPACER, FOURTH 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 and align the ring slots with the shift keys.




d. Using SST and a press, install the rear ball bearing.
SST 09608-12010 (09608-00070)







6. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.




7. INSPECT FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure 4th gear thrust clearance.

Standard clearance: 0.20 - 0.45 mm (0.0078 - 0.0177 in.)