Inspection
INSPECTIONInspect all parts, and repair or replace as necessary.
Each gear and main drive gear
1. Inspect synchronizer cones for wear.
2. Inspect individual gear teeth for damage, wear, cracks.
3. Inspect synchronizer ring matching teeth for damage or wear.
4. Inspect main drive gear splines for damage or wear.
Mainshaft
1 Measure the mainshaft runout.
Maximum: O.O3mm {O.OO12 in}
2. Inspect splines for damage or wear.
Countershaft
1. Inspect gear teeth for damage, wear, cracks.
2. Inspect splines for damage or wear.
Clutch hub assembly
1. Inspect for clutch hub sleeve and hub operation.
2. Inspect individual gear teeth for damage, wear, cracks.
3. Inspect synchronizer key for damage, wear, cracks.
4 Measure the clearance between hub sleeve and release fork.
Standard clearance: O.2-O.3mm {O.008-O.O11 in}
Maximum: O.5mm (0.019 in)
Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear, cracks.
2. Inspect taper surface for wear or cracks.
Note: Set the synchronizer ring squarely in the gear; then measure around the circumference.
3. Measure the clearance between synchronizer ring and flank surface of gear.
Standard clearance: 1.5mm {O.059 in}
Minimum: O.8mm {O.O31 in}
Bearing
Inspect for damage or rough rotation.
Reverse idler gear and shaft
1. Inspect gear teeth for damage, wear, cracks.
2. Measure the clearance between reverse idle gear bush and shaft.
Standard clearance: O.02-O.O5mm {O.0008-O.0019 in}
Maximum: O.15mm {O.006 in}