INPUT SHAFT > INSPECTION

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1. INSPECT 4TH GEAR THRUST CLEARANCE


    C069546

  1. Using a feeler gauge, measure the 4th gear thrust clearance.

    Standard clearance:
    0.10 to 0.57 mm (0.00393 to 0.0224 in.)
    If the clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear, or input shaft rear radial ball bearing.


2. INSPECT 3RD GEAR THRUST CLEARANCE


    C176301

  1. Using a dial indicator, measure the 3rd gear thrust clearance.

    Standard clearance:
    0.10 to 0.35 mm (0.00393 to 0.0138 in.)
    If the clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear, or input shaft.


3. INSPECT 4TH GEAR RADIAL CLEARANCE


    C069548

  1. Using a dial indicator, measure the 4th gear radial clearance.

    Standard Clearance:
    Bearing
    		Standard Clearance
    mm (in.)
    KOYO made
    		0.009 to 0.053
    (0.000354 to 0.00208)
    NSK made
    		0.009 to 0.051
    (0.000354 to 0.00201)
    If the clearance is out of specification, replace the 4th gear, needle roller bearing, or input shaft.


4. INSPECT 3RD GEAR RADIAL CLEARANCE


    C069549

  1. Using a dial indicator, measure the 3rd gear radial clearance.

    Standard Clearance:
    Bearing
    		Standard Clearance
    mm (in.)
    KOYO made
    		0.009 to 0.053
    (0.000354 to 0.00208)
    NSK made
    		0.009 to 0.051
    (0.000354 to 0.00201)
    If the clearance is out of specification, replace the 3rd gear, needle roller bearing, or input shaft.


5. INSPECT INPUT SHAFT


    C069620

  1. Using V-blocks and a dial indicator, inspect the shaft for runout.

    Maximum runout:
    0.03 mm (0.00118 in.)
    If the runout exceeds the maximum, replace the input shaft.


    C092870E02

  1. Using a micrometer, measure the outside diameter of the input shaft journal surface.

    Outside Diameter:
    Part
    		Standard Outside Diameter
    mm (in.)
    		Minimum Outside Diameter
    mm (in.)
    A
    		35.984 to 36.000
    (1.4167 to 1.4173)
    		35.984
    (1.4167)
    B
    		35.984 to 36.000
    (1.4167 to 1.4173)
    		35.984
    (1.4167)
    C
    		27.957 to 27.972
    (1.1007 to 1.1013)
    		27.957
    (1.1007)
    If the outside diameter is less than the minimum, replace the input shaft.


6. INSPECT 4TH GEAR


    C069622

  1. Using a cylinder gauge, measure the inside diameter of the 4th gear.

    Inside diameter:
    Standard Inside diameter
    mm (in.)
    		Maximum Inside Diameter
    mm (in.)
    42.009 to 42.025
    (1.6539 to 1.6545)
    		42.025
    (1.6545)
    If the inside diameter exceeds the maximum, replace the 4th gear.


7. INSPECT 3RD GEAR


    C069622

  1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

    Inside Diameter:
    Standard Inside Diameter
    mm (in.)
    		Maximum Inside Diameter
    mm (in.)
    43.009 to 43.025
    (1.6933 to 1.6939)
    		43.025
    (1.6939)
    If the inside diameter exceeds the maximum, replace the 3rd gear.


8. INSPECT NO. 4 SYNCHRONIZER RING


    C069623

  1. Coat the 4th gear cone with gear oil. Turn the No. 4 synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks.
    If the No. 4 synchronizer ring does not lock, replace the ring or the 4th gear.



    C069624

  1. Using a feeler gauge, measure the clearance between the No. 4 synchronizer ring back and 4th gear spline end.

    Standard clearance:
    0.75 to 1.65 mm (0.0295 to 0.0650 in.)
    If the clearance is out of specification, replace the synchronizer ring.


9. INSPECT NO. 3 SYNCHRONIZER RING


    C069625

  1. Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.
    If the synchronizer outer ring does not lock, replace the ring or the 3rd gear.



    C069626

  1. Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end.

    Standard clearance:
    0.65 to 1.75 mm (0.0256 to 0.0689 in.)
    If the clearance is out of specification, replace the No. 3 synchronizer ring.


10. INSPECT NO. 2 TRANSMISSION HUB SLEEVE


    C067843

  1. Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.

  1. Inspect the tip of the spline gear on the No. 2 transmission hub sleeve for wear.
    If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.



    C070506E02

  1. Using a vernier caliper, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.

    Standard clearance:
    0.11 to 0.69 mm (0.00433 to 0.0272 in.) {A - B}
    If the clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork with new ones.