OUTPUT SHAFT INSPECTION


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A01KG5X

      Using a feeler gauge, check the thrust clearance of the 1st gear.

      Standard clearance
      0.20 to 0.45 mm (0.0079 to 0.0177 in.)

  2. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A01KGGO

      Using a feeler gauge, check the thrust clearance of the 2nd gear.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)

  3. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A01KIKD

      Using a feeler gauge, check the thrust clearance of the 3rd gear.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)

  4. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A01KH70

      Using a dial indicator, check the radial clearance of the 1st gear.

      Standard clearance
      0.020 to 0.073 mm (0.0008 to 0.0029 in.)

      If the clearance is out of the specification, replace the 1st gear needle roller bearing with a new one.

  5. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A01KFQT

      Using a dial indicator, check the radial clearance of the 2nd gear.

      Standard clearance
      0.015 to 0.068mm (0.0006 to 0.0027 in.)

      If the clearance is out of the specification, replace the 2nd gear needle roller bearing with a new one.

  6. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01KHFA

      Using a dial indicator, check the radial clearance of the 3rd gear.

      Standard clearance
      0.015 to 0.068 mm (0.0006 to 0.0027 in.)

      If the clearance is out of the specification, replace the 3rd gear needle roller bearing with a new one.

  7. INSPECT OUTPUT SHAFT


    1. A01KF3O

      Using a dial indicator, check the output shaft runout.

      Maximum runout
      0.03 mm (0.0012 in.)

      If the bend exceeds the specification, replace the output shaft with a new one.

    2. A01KHSR

      Using a micrometer, check the outer diameter of the output shaft shown position in the diagram.

      Standard diameter
      A
      38.979 to 38.995 mm (1.5334 to 1.5352 in.)
      B
      46.984 to 47.000 mm (1.8498 to 1.8504 in.)
      C
      37.984 to 38.000 mm (1.4954 to 1.4961 in.)
      Minimum diameter
      A
      38.979 mm (1.5334 in.)
      B
      46.984 mm (1.8498 in.)
      C
      37.984 mm (1.4954 in.)

      If the outer diameter is the limit or less, replace the output shaft with a new one.

    3. A01KHDR

      Using a micrometer, check the thickness of the output shaft flange shown position in the diagram.

      Standard clearance
      4.8 to 5.2 mm (0.1890 to 0.2047 in.)

      If the clearance is out of the specification, replace the output shaft.

  8. INSPECT 3RD GEAR


    1. A01KHQ8

      Using a cylinder gauge, check the inner diameter of the 3rd gear.

      Standard clearance
      44.015 to 44.040 mm (1.7329 to 1.7339 in.)
      Maximum clearance
      44.040 mm (1.7339 in.)

      If the inner diameter exceeds the limit, replace the 3rd gear with a new one.

  9. INSPECT 2ND GEAR


    1. A01KHMV

      Using a cylinder gauge, check the inner diameter of the 2nd gear.

      Standard clearance
      53.015 to 53.040 mm (2.0872 to 2.0881 in.)
      Maximum clearance
      53.040 mm (2.0881 in.)

      If the inner diameter exceeds the limit, replace the 2nd gear with a new one.

  10. INSPECT 1ST GEAR


    1. A01KHT0

      Using a cylinder gauge, check the inner diameter of the 1st gear.

      Standard clearance
      46.015 to 46.040 mm (1.8116 to 1.8126 in.)
      Maximum clearance
      46.040 mm (1.8126 in.)

      If the inner diameter exceeds the limit, replace the 2nd gear with a new one.

  11. INSPECT 1ST GEAR THRUST WASHER


    1. A01KG4C

      Using a micrometer, check the thickness of the 1st gear thrust washer.

      Standard clearance
      5.96 to 6.05 mm (0.2343 to 0.2382 in.)
      Minimum clearance
      5.96 mm (0.2343 in.)

  12. INSPECT SYNCHRONIZER RING NO.1 (FOR FIRST SYNCHRONIZER RING)


    1. A01KEUJ

      Apply gear oil to the cone of the 1st gear, and check that it does not rotate to the circumference direction while the synchronizer ring No. 1 (for first synchronizer ring) is pushed.

    2. A01KH9M

      Check the clearance between the synchronizer ring No. 1 (for first synchronizer ring) and the 1st gear while the synchronizer ring No. 1 (for first synchronizer ring) is pushed to the cone of the 1st gear.

      Standard clearance
      0.75 to 1.65 mm (0.0295 to 0.0649 in.)

      If the clearance is out of the specification, replace the synchronizer ring No. 1 (for first synchronizer ring) with a new one.

  13. INSPECT SYNCHRONIZER RING NO.1 (FOR SECOND SYNCHRONIZER RING)


    1. A01KEIM

      Apply gear oil to the cone of the 2nd gear, and check that it does not rotate to the circumference direction while the synchronizer ring No. 1 (for second synchronizer ring) is pushed.

    2. A01KHTE

      Check the clearance between the synchronizer ring No. 1 (for second synchronizer ring) and the 2nd gear while the synchronizer ring No. 1 (for second synchronizer ring) is pushed to the cone of the 2nd gear.

      Standard clearance
      0.75 to 1.65 mm (0.0295 to 0.0649 in.)

      If the clearance is out of the specification, replace the synchronizer ring No. 1 (for second synchronizer ring) with a new one.

  14. INSPECT SYNCHRONIZER RING NO.2 (FOR THIRD SYNCHRONIZER RING)


    1. A01KFRL

      Apply gear oil to the cone of the 3rd gear, and check that it does not rotate to the circumference direction while the synchronizer ring No. 2 (for third synchronizer ring) is pushed.

    2. A01KFQO

      Check the clearance between the synchronizer ring No. 2 (for third synchronizer ring) and the 3rd gear while the synchronizer ring No. 2 (for third synchronizer ring) is pushed to the cone of the 3rd gear.

      Standard clearance
      0.75 to 1.65 mm (0.0295 to 0.0649 in.)

      If the clearance is out of the specification, replace the synchronizer ring No. 2 (for third synchronizer ring) with a new one.

  15. INSPECT REVERSE GEAR


    1. A01KGT5

      Using a vernier caliper, check the reverse gear groove and the thickness of the gear shift fork claw No. 1 clearance.

      Standard clearance
      0.15 to 0.41 mm (0.0060 to 0.0161 in.)

      If the clearance is out of the specification, replace the reverse gear and the No. 1 gear shift fork with new ones.

  16. INSPECT TRANSMISSION CLUTCH HUB NO.1


    1. A01KINM

      Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.

    2. Check the tip of the spline gear of the sleeve of the reverse gear for wear.

  17. INSPECT TRANSMISSION HUB SLEEVE NO.2


    1. A01KHBW

      Using a vernier caliper, check the transmission hub sleeve No. 2 groove and the thickness of the gear shift fork claw No. 2.

      Standard clearance
      0.15 to 0.35 mm (0.0059 to 0.0138 in.)

      If the clearance is out of the specification, replace the transmission hub sleeve No. 2 and the No. 2 gear shift fork with new ones.

  18. INSPECT TRANSMISSION CLUTCH HUB NO.2


    1. A01KIJ6

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

    2. Check the tip of the spline gear of the sleeve of the reverse gear for wear.