Mainshaft: Service and Repair
TOOL REQUIRED- 07746-0030100 Driver, 40 mm I.D.
- 07746-0030400 Attachment, 35 mm I.D.
- 07746-0030300 Attachment, 30 mm I.D.
- Or Equivalent
DISASSEMBLE
NOTE: Before disassembling, inspect the gear clearances. Testing and Inspection
1. Remove the interlock guide bolt from under the clutch housing.
2. Remove the shift arm B attaching bolt.
3. Remove the mainshaft and countershaft assemblies with the shift fork from the clutch housing.
NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft splines to protect the seal.
4. Inspect mainshaft assembly clearance.
5. Remove the ball bearing using a bearing puller as shown.
CAUTION: Remove the synchro hubs using a press and steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.
6. Support 4th gear on steel blocks, and press the main shaft out of the 5th synchro hub as shown.
7. Support the 3rd gear on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub as shown.
INSPECT
1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B. C, and D.
Standard:
A: 21.987 - 22.000 mm (0.8656 - 0.8661 inch)
B: 26.980 - 26.993 mm (1.0622 - 1.0627 inch)
C: 33.984 - 34.000 mm (1.3380 - 1.3386 inch)
D: 25.977 - 25.990 mm (1.0227 - 1.0232 inch)
Service Limit:
A: 21.930 mm (0.8634 inch)
B: 26.930 mm (1.0602 inch)
C: 33.930 mm (1.3358 inch)
D: 25.920 mm (1.0205 inch)
NOTE: If any part of the mainshaft is less than the service limit, replace it with a new one.
2. Inspect for runout.
- Standard (max): 0.02 mm (0.001 inch)
- Service Limit: 0.05 mm (0.002 inch)
NOTE: Support the mainshaft at both ends as shown. If the runout is more than the service limit, replace the mainshaft with a new one.
ASSEMBLE
CAUTION: When installing the 3rd/4th and 5th synchro hubs, support the shaft on steel blocks, and install the synchro hubs using a press.
NOTE: Refer to disassemble for reassembly sequence.
1. Support 2nd gear on steel blocks, then install the 3rd/4th synchro hub using the special tools and a press as shown.
2. Install the 3rd/4th synchro sleeve by aligning the stops of the 3rd/4th synchro sleeve and hub.
NOTE: After installing, Check the operation of the 3rd/4th synchro hub set.
3. Install the 5th synchro hub using the special.tools and a press as shown.
4. Install the ball bearing using the special tools and a press as shown.
NOTE: Install the ball bearing with the tapered end facing down.