Inspection

GEARS
1. Inspect the synchronizer cones for wear.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer ring matching teeth for damage and wear.





SYNCHRONIZER RING
1. Inspect the synchronizer ring teeth for damage, wear, and cracks.
2. Inspect the tapered surface for wear and cracks.
3. Set the synchronizer ring squarely in the gear.





4. Measure the clearance between the synchronizer ring and the flank surface of the gear all around the circumference. Standard clearance is 1.50 mm (0.059 inch) and the minimum is 0.80 mm (0.031 inch).





CLUTCH HUB ASSEMBLY
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer keys for damage, wear, and cracks.








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





BEARING
Inspect for damage and rough rotation.

PRIMARY SHAFT GEAR AND SECONDARY SHAFT GEAR
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the on passage for blockage.








5. Measure the shaft gear runout. Primary shaft gear runout is 0.050 mm (0.0020 inch) maximum and secondary shaft gear runout is 0.015 mm (0.0006 inch) maximum.











6. Measure the clearance between the shaft and the gears.





REVERSE IDLER GEAR
1. Inspect the gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bushing and the reverse lever. Standard clearance is 0.10 - 0.35 mm (0.00 - 0.014 inch) and maximum is 0.85 mm (0.033 inch).