Output Shaft
DISASSEMBLY
1. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 - 0.35 mm (0.0039 - 0.0138 inch)
2nd gear: 0.10 - 0.45 mm (0.0039 - 0.0177 inch)
2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
Standard clearance:
1st gear: 0.009 - 0.051 mm (0.0004 - 0.0020 inch)
2nd gear: 0.009 - 0.053 mm (0.0004 - 0.0021 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER
a. Using a press, remove the bearing and 4th driven gear.
b. Remove the spacer.
4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING
6. REMOVE SNAP RING
Using a snap ring expander, remove the snap ring.
7. REMOVE NO. 1 HUB SLEEVE ASSEMBLY AND 1ST GEAR
Using a press, remove the No. 1 hub sleeve assembly and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE ROLLER BEARING
9. REMOVE OUTPUT SHAFT FRONT BEARING
Using SST, remove the output shaft front bearing.
SST 09950-00020, 09950-00030
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 gear spline end.
Minimum clearance: 0.8 mm (0.031 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.
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 it does not lock, replace the synchronizer ring.
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. MEASURE NO. 1 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. 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: 38.984 mm (1.5348 inch)
c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 inch)
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 clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.
NOTICE: Position the key springs so that their end gaps are not aligned.
2. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RING AND NO. 1 HUB SLEEVE ASSEMBLY TO OUTPUT SHAFT
a. Apply MP grease to the needle roller bearing.
b. Install the needle roller bearing and 1st gear.
c. Place the synchronizer ring (for the 1st gear) on the gear and align the ring slots with the shifting keys.
d. Using SST and a press, install the 1st gear and No. 1 hub sleeve assembly.
SST 09316-60011 (09310-00041)
3. INSTALL SNAP RING
a. Select a snap ring that allows the minimum axial play.
b. Using a snap ring expander, install the snap ring.
4. MEASURE 1ST GEAR THRUST CLEARANCE
5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR
a. Install the spacer.
b. Apply MP grease to the needle roller bearing.
c. Place the synchronizer rings (for the 2nd gear) on the gear.
NOTICE: Do not install the synchronizer ring for the 1st gear.
d. Install the 2nd gear.
e. Using a press, install the 3rd driven gear.
NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring.
6. MEASURE 2ND GEAR THRUST CLEARANCE
7. INSTALL SPACER AND 4TH DRIVEN GEAR
a. Install the spacer.
b. Using a press, install the 4th driven gear.
8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 0950-30012
9. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316-60011 (09316-00071)