#
5TH/REVERSE GEAR AND HOUSING PARTS INSPECTION

BME051501029304

## 5th and Reverse 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.

## 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}
  Minimum: 0.80 mm {0.031 in}

## 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 fork.

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

  Clearance
  Standard: 0.10-0.36 mm {0.004-0.014 in}
  Maximum: 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 any malfunction, replace the reverse idle gear.

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

  • If it exceeds the maximum specification, replace if necessary.

  Clearance
  Standard: 0.10-0.35 mm {0.004-0.013 in}
  Maximum: 0.85 mm {0.033 in}

## 5th Gear and Sleeve Inspection

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

  • If not within the specification, replace parts if 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}