Inspection

Shift Control Components
INSPECTION





^ Check contact and sliding surfaces of fork rods for wear, scratches, projections and other damage.

Gear Components
INSPECTION








Gears and Shafts
^ Check shafts for cracks, wear and bending.
^ Check gears for excessive wear, chips and cracks.

Synchronizers





^ Check spline portion of coupling sleeves, synchronizer hubs, and gears for wear, chips, and cracks.
^ Check baulk rings for cracks and deformation.
^ Check shifting inserts for wear and deformation.
^ Check insert spread springs for deformation.





^ Measure wear of main drive, 1st and OD baulk rings.
Clearance between baulk ring and gear: Refer to Specifications.
^ If the clearance is smaller than the wear limit, replace baulk ring.





^ Measure 2nd and 3rd baulk ring wear.
1) Place baulk rings in position on synchronizer cone.
2) While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B".
Standard:
Inner "A": 0.7 - 0.9 mm (0.028 - 0.035 inch)
Outer "B": 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit: 0.2 mm (0.008 inch)





^ If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.





^ Measure wear of reverse baulk ring.
a) Place baulk ring in position on reverse cone.
b) While holding baulk ring against reverse cone as far as it will go, measure dimension "A" with dial indicator. Dimension "A":
Standard: -0.1 to 0.35 mm (-0.0039 to 0.0138 inch)
Wear limit: 0.7 mm (0.028 inch)
c) If dimension "A" is larger than the wear limit, replace baulk ring.

Bearings





^ Make sure all bearings roll freely and are free from noise, cracks, pitting or wear.