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PRIMARY SHAFT COMPONENTS INSPECTION

BME051517201303

## 4th Gear, 3rd Gear Inspection

1. Inspect the synchronizer cones for wear.

  • If there is any malfunction, replace parts if necessary.

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

  • If there is any malfunction, replace parts if necessary.

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

  • If there is any malfunction, replace the synchronizer ring.

## 4th Synchronizer Ring, 3rd Synchronizer Ring Inspection

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

  • If there is any malfunction, replace parts if necessary.

2. Inspect the tapered surface for wear and cracks.

  • If there is any malfunction, replace parts if necessary.

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

  • If it is less than the minimum specification, replace the synchronizer ring.

  Note

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

  Clearance
  Standard: 1.50 mm {0.059 in}
  Maximum: 0.80 mm {0.031 in}

## 3rd/4th Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.

  • If there is any malfunction, replace parts if necessary.

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

  • If there is any malfunction, replace parts if necessary.

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

  • If there is any malfunction, replace parts if necessary.

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

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

  Clearance
  Standard: 0.10-0.40 mm {0.004-0.015 in}
  Maximum: 0.90 mm {0.035 in}

## Primary Shaft Gear Inspection

1. Inspect the gear contact surface for damage and wear.

  • If there is any malfunction, replace the primary shaft.

2. Inspect the splines for damage and wear.

  • If there is any malfunction, replace the primary shaft.

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

  • If there is any malfunction, replace the primary shaft.

4. Inspect the oil passage for clogging.

  • If there is any malfunction, replace the primary shaft.

5. Measure the shaft gear runout.

  • If it exceeds the maximum specification, replace the primary shaft.

  Maximum runout
  0.050 mm {0.0020 in}

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

  • If not within the specification, replace parts if necessary.
mm {in}

Gear | Shaft (Outer dia.) | Gear (Inner dia.) | Clearance
--- | --- | --- | ---
3rd | 35.945-35.970 {1.415-1.416} | 36.000-36.025 {1.417-1.418} | 0.030-0.080 {0.001-0.003}
4th | 30.945-30.970 {1.218-1.219} | 31.000-31.025 {1.220-1.221}