Output Shaft

DISASSEMBLY





1. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Maximum clearance:
1st gear: 0.40 mm (0.0157 inch)
2nd gear: 0.35 mm (0.0138 inch)





2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
Maximum clearance: 1st and 2nd gears: 0.053 mm (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 RINGS
6. REMOVE INNER RACE AND BALL FROM OUTPUT SHAFT





7. REMOVE NO. 1 HUB SLEEVE ASSEMBLY AND 1ST GEAR
Using a press, remove the No. 1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RINGS AND NEEDLE ROLLER BEARING





9. REMOVE 1ST GEAR BEARING INNER RACE
Using SST and a press, remove the 1st gear bearing inner race.
SST 09950-00020





10. DISASSEMBLY NO. 1 HUB SLEEVE ASSEMBLY
a. Remove the No. 1 hub sleeve from the No. 1 clutch hub.
b. Remove the 3 shifting keys and springs from the No. 1 clutch hub.





11. REMOVE OUTPUT SHAFT FRONT SEARING
Using SST, remove the output shaft front bearing.
SST 09950-00020, 09950-00030

INSPECTION
1. INSPECT GEAR SYNCHRONIZER RINGS
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.





2. 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: 0.35 mm (0.0138 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. 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:
Part A: 37.610 mm (1.4807 inch)
Part B: 34.502 mm (1.3583 inch)





c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.03 mm (0.0012 inch)

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.





1. INSTALL NO. 1 CLUTCH HUB INTO NO. 1 HUB SLEEVE
a. Install the 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.

NOTICE: Assemble the clutch hub and hub sleeve in the direction shown in the illustration.





2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09500-35010

HINT: Align the hole of the output shaft and inner race.

3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RINGS AND NO. 1 HUB SLEEVE TO OUTPUT SHAFT
a. Apply MP grease to the needle roller bearing and install it.





b. Place the synchronizer rings on the 1st gear.
c. Install the 1st gear.





d. Using SST and a press, install the 1st gear and No. 1 hub sleeve.
SST 09316-60011 (09316-00041)
4. MEASURE 1ST GEAR THRUST CLEARANCE





5. INSTALL BALL AND INNER RACE TO OUTPUT SHAFT

HINT: Align the groove of the inner race and ball.

6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RINGS, 2ND GEAR AND 3RD DRIVEN GEAR
a. Install the spacer.





b. Apply MP grease to the needle roller bearing.
c. Place the synchronizer rings on the 2nd 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.

7. MEASURE 2ND GEAR THRUST CLEARANCE





8. INSTALL SPACER AND 4TH DRIVEN GEAR
a. Install the spacer.
b. Using a press, install the 4th driven gear.





9. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install a new bearing.
SST 09500-30012





10. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316-60011 (09310-00071)