OUTPUT SHAFT INSPECTION


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A01KHW6E22

      Using a dial indicator, measure 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. A01KHW6E23

      Using a dial indicator, measure 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. A01KIKDE04

      Using a feeler gauge, measure 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, measure 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 not within the specified values, replace the 1st gear needle roller bearing with a new one.

  5. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A01KFQT

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

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

      If the clearance is not within the specified values, replace the 2nd gear needle roller bearing with a new one.

  6. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01KHFA

      Using a dial indicator, measure 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 not within the specified values, replace the 3rd gear needle roller bearing with a new one.

  7. INSPECT OUTPUT SHAFT


    1. A01KF1M

      Using a dial indicator, measure the runout of the output shaft.

      Maximum runout
      0.03 mm (0.0012 in.)

      If the runout is greater than the maximum, replace the output shaft with a new one.

    2. A01KGN8E01

      Using a micrometer, measure the outer diameter of the output shaft at points A, B and C.

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

      If the outer diameter is less than the minimum, replace the output shaft with a new one.

    3. A01KHDR

      Using a micrometer, measure the thickness of the output shaft flange as shown in the illustration.

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

      If the thickness is not within the specified values, replace the output shaft.

  8. INSPECT 3RD GEAR


    1. A01KHQ8

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

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

      If the inner diameter is greater than the maximum, replace the 3rd gear with a new one.

  9. INSPECT 2ND GEAR


    1. A01KHMV

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

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

      If the inner diameter is greater than the maximum, replace the 2nd gear with a new one.

  10. INSPECT 1ST GEAR


    1. A01KHT0

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

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

      If the inner diameter is greater than the maximum, replace the 1st gear with a new one.

  11. INSPECT 1ST GEAR THRUST WASHER


    1. A01KG4C

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

      Standard thickness
      5.95 to 6.05 mm (0.2343 to 0.2382 in.)
      Minimum thickness
      5.95 mm (0.2343 in.)

      If the thickness is less than the minimum, replace the 1st gear thrust washer.

  12. INSPECT NO. 1 SYNCHRONIZER RING SET (for 1st Gear (for Triple Type Synchronizer Ring))


    1. A01KHLG

      Apply gear oil to the cone of the 1st gear, and check that it does not turn in either direction while pushing the No. 1 synchronizer ring set (for the 1st gear).

      If it turns, replace the No. 1 synchronizer ring set.

    2. A01KI9H

      Measure the clearance between the No. 1 synchronizer ring set (for the 1st gear) and 1st gear while pushing the No. 1 synchronizer ring set against the cone of the 1st gear.

      Standard clearance
      0.65 to 1.75 mm (0.0255 to 0.0688 in.)

      If the clearance is not within the specified values, replace the No. 1 synchronizer ring set (for the 1st gear) with a new one.

  13. INSPECT NO. 1 SYNCHRONIZER RING (for 1st Gear (for Single Type Synchronizer Ring))


    1. A01KG1B

      Apply gear oil to the cone of the 1st gear, and check that it does not turn in either direction while pushing the No. 1 synchronizer ring (for the 1st gear).

      If it turns, replace the No. 1 synchronizer ring.

    2. A01KFDM

      Measure the clearance between the No. 1 synchronizer ring (for the 1st gear) and 1st gear while pushing the No. 1 synchronizer ring against the cone of the 1st gear.

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

      If the clearance is not within the specified values, replace the No. 1 synchronizer ring (for the 1st gear) with a new one.

  14. INSPECT NO. 1 SYNCHRONIZER RING SET (for 2nd Gear (for Triple Type Synchronizer Ring))


    1. A01KGWK

      Apply gear oil to the cone of the 2nd gear, and check that it does not turn in either direction while pushing the No. 1 synchronizer ring set (for the 2nd gear).

      If it turns, replace the No. 1 synchronizer ring set.

    2. A01KHON

      Measure the clearance between the No. 1 synchronizer ring set (for the 2nd gear) and 2nd gear while pushing the No. 1 synchronizer ring set against the cone of the 2nd gear.

      Standard clearance
      0.65 to 1.75 mm (0.0255 to 0.0688 in.)

      If the clearance is not within the specified values, replace the No. 1 synchronizer ring set (for the 2nd gear) with a new one.

  15. INSPECT NO. 1 SYNCHRONIZER RING (for 2nd Gear (for Single Type Synchronizer Ring))


    1. A01KGWK

      Apply gear oil to the cone of the 2nd gear, and check that it does not turn in either direction while pushing the No. 1 synchronizer ring (for the 2nd gear).

      If it turns, replace the No. 1 synchronizer ring.

    2. A01KHON

      Measure the clearance between the No. 1 synchronizer ring (for the 2nd gear) and 2nd gear while pushing the No. 1 synchronizer ring against the cone of the 2nd gear.

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

      If the clearance is not within the specified values, replace the No. 1 synchronizer ring (for the 2nd gear) with a new one.

  16. INSPECT NO. 2 SYNCHRONIZER RING (for 3rd Gear)


    1. A01KFRL

      Apply gear oil to the cone of the 3rd gear, and check that it does not turn in either direction while pushing the No. 2 synchronizer ring (for the 3rd gear).

      If it turns, replace the No. 2 synchronizer ring.

    2. A01KFQO

      Measure the clearance between the No. 2 synchronizer ring (for the 3rd gear) and 3rd gear while pushing the No. 2 synchronizer ring (for the 3rd gear) against the cone of the 3rd gear.

      Standard clearance
      0.75 to 1.65 mm (0.0295 to 0.0650 in.)

      If the clearance is not within the specified values, replace the No. 2 synchronizer ring (for the 3rd gear) with a new one.

  17. INSPECT REVERSE GEAR


    1. A01KGT5E06

      Using vernier calipers, measure the width of the reverse gear groove and the thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.

      Standard clearance (A - B)
      0.15 to 0.41 mm (0.0059 to 0.0161 in.)

      If the clearance is not within the specified values, replace the reverse gear and the No. 1 gear shift fork with new ones.

  18. INSPECT NO. 1 TRANSMISSION CLUTCH HUB


    1. A01KINM

      Check that the No. 1 transmission clutch hub and reverse gear slide smoothly each other.

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

      If there are any defects, replace the No. 1 transmission clutch hub.

  19. INSPECT NO. 2 TRANSMISSION HUB SLEEVE


    1. A01KHBWE05

      Using vernier calipers, measure the width of the No. 2 transmission hub groove and the thickness of the claw of the No. 2 gear shift fork.

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

      If the clearance is not within the specified values, replace the No. 2 transmission hub sleeve and the No. 2 gear shift fork with new ones.

  20. INSPECT NO. 2 TRANSMISSION CLUTCH HUB


    1. A01KIJ6

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

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