Input Shaft Assembly

Components:

INPUT SHAFT DISASSEMBLY








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

Standard clearance:
3rd gear
0.10 - 0.35 mm (0.0039 - 0.0138 in.)
4th gear
0.10 - 0.55 mm (0.0039 - 0.0217 in.)

Maximum clearance:
3rd gear
0.40 mm (0.0157 in.)
4th gear
0.60 mm (0.0236 in.)




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

Standard clearance:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)

Maximum clearance:
0.070 mm (0.0028 in.)

If the clearance exceeds the minimum, replace the gear, needle roller bearing and shaft.




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




4. REMOVE REAR BALL BEARING, FOURTH GEAR, NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT
a. Using SST and a press, remove the rear ball bearing.
SST 09950-00020
b. Remove the 4th gear, needle roller bearing, spacer and synchronizer ring.




5. REMOVE SNAP RING
Using two screwdrivers and a hammer, tap out the snap ring.




6. REMOVE NO.2 HUB SLEEVE ASSEMBLY, THIRD GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER BEARING
Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearing.
SST 09950-00020




7. REMOVE NO.2 HUB SLEEVE, SHIFTING KEYS AND SPRINGS FROM NO.2 CLUTCH HUB
Remove the three shifting keys and springs from the No.2 clutch hub.

INPUT SHAFT COMPONENT PARTS INSPECTION




1. INSPECT 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 and check that the ring is locked.
If braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTE:
- Wash off completely the fine lapping compound after rubbing.
- Check again the braking effect of the synchronizer ring.




c. Measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

HINT:
- When replacing either a synchronizer ring or gear, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
- When replacing both the synchronizer ring and gear, there is no need to apply any compound or to rub them together.

NOTE: Wash off completely the fine lapping compound after rubbing.




2. INSPECT CLEARANCE OF 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.)

HINT:
- When replacing either a synchronizer ring or gear, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
- When replacing both the synchronizer ring and gear, there is no need to apply any compound or to rub them together.




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
24.870 mm (0.9791 in.)
Part B
28.970 mm (1.1405 in.)
Part C
30.970 mm (1.2193 in.)
Part D
24.970 mm (0.9831 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.

INPUT SHAFT ASSEMBLY

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




1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the three sprigs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.




2. INSTALL THIRD GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply gear oil to the needle roller bearing.
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
a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and a hammer, tap in the snap ring.




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

Standard clearance:
0.10 - 0.35 mm (0.0039 - 0.0138 in.)

5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARING, SPACER, FOURTH GEAR AND REAR BALL BEARING




a. Apply gear oil to the needle roller bearing.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




c. Using SST and a press, install the rear ball bearing.
SST 09608-2001 2(09608-03070)







6. INSTALL SNAP RING
a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and a hammer, tap in the snap ring.




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

Standard clearance:
0.10 - 0.56 mm (0.0039 - 0.0217 in.)