5TH/REVERSE GEAR AND HOUSING PARTS INSPECTION

5th and Reverse Gear Inspection

1. Inspect the synchronizer cones for wear.

• If there is malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

3. Inspect the synchronizer ring matching teeth for damage and wear.

• If there is malfunction, replace the synchronizer ring.

Synchronizer Ring Inspection

1. Inspect the synchronizer ring teeth for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

2. Inspect the tapered surface for wear and cracks.

• If there is malfunction, replace parts as necessary.

3. Measure the clearance between the synchronizer ring and the flank surface of the gear.

• If not as specified, replace the synchronizer ring.

Note

• Set the synchronizer ring squarely in the gear; then measure around the circumference.

Standard clearance

1.50 mm {0.059 in}

Minimum

0.80 mm {0.031 in}

Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.

• If there is malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

3. Inspect the synchronizer keys for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

4. Measure the clearance between the hub sleeve and shift fork.

• If the clearance exceeds the maximum, replace the hub sleeve and shift fork as a set.

Standard clearance

0.10-0.36 mm {0.004-0.014 in}

Maximum clearance

0.86 mm {0.034 in}

Reverse Idle Gear and Reverse Lever Inspection

1. Inspect the gear teeth for damage, wear, and cracks.

• If there is malfunction, replace the reverse idle gear.

2. Measure the clearance between the reverse idle gear bushing and the reverse lever.

• If not as specified, replace as necessary.

Standard clearance

0.10-0.35 mm {0.004-0.013 in}

Maximum Clearance

0.85 mm {0.033 in}

5th Gear and Sleeve Inspection

1. Measure the clearance between the 5th gear and the Sleeve.

• If not as specified, replace parts as necessary.

5th gear inner diameter

34.000-34.025 mm {1.3386-1.3395 in}

Sleeve outer diameter

33.945-33.970 mm {1.3365-1.3373 in}

Clearance

0.030-0.080 mm {0.0012-0.0031 in}