Part 2
Shifter Fork and Rod (Continued)3RD-4TH FORK ROD SELECTION
NOTE:
In the following conditions, perform the procedures below.
^ When the main shaft is replaced.
^ When the 3rd, and 3rd to 6th drive gear and bushing are replaced.
^ When the 3rd, and 3rd to 6th synchro assemblies are replaced.
^ When the 3rd-4th hub and sleeve assemblies are replaced.
1) Insert the main shaft assembly into the adapter plate.
2) Set the height gauge to the adapter plate. Lower the height gauge indicator to the top surface of the snap ring groove, and set to the 0 point on the upper side of the main rear bearing.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ The height gauge will be set on the adapter plate during the measurement. Use a scraper to remove any gasket material remaining on the end face.
^ During measurement, do not place the height gauge in the shaded area shown in the figure.
3) Use a height gauge to measure "C1" and "C2" as shown in the figure.
(1) Shift the 3rd-4th sleeve to the 4th gear side, push up on the stopper, and measure "C2".
NOTE:
^ Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure.
^ Turn dial (2), and set the indicator to the 4th side end surface of the sleeve.
^ The measurement is to be performed with 2 persons, while holding the sleeve straight.
^ Turn approximately 72° at a time, and measure the sleeve in 5 locations. Round off the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2) Set the height gauge indicator upside down.
(3) Shift the 3rd-4th sleeve to the 3rd drive gear side, push down to the stopper, and measure "C1".
NOTE:
^ Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 3rd side end surface of the sleeve.
^ Turn approximately 72° at a time, and measure the sleeve in 5 locations. Round off the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
4) According to both of the measurements, calculate the neutral position of the 3rd-4th sleeve. From the following calculation, select a fork rod which matches the calculated value.
Calculation: T = (C1 + C2) / 2
T: 3rd-4th sleeve center position
C1: Measured depth from the main shaft rear bearing snap ring groove to the sleeve end, when shifted to 3rd gear: +55 mm (2.17 in)
C2: Measured depth from the main shaft rear bearing snap ring groove to the sleeve end, when shifted to 4th gear
NOTE: Attach the indicator upside down in comparison to the setting procedures for the 0 point. Add dl [Numerical value: 55 mm (2.17 in)] from the figure below to "C1", and measure "C1".
5TH-6TH FORK ROD SELECTION
NOTE:
In the following conditions, perform the procedures below.
^ When the main shaft is replaced.
^ When the 3rd to 6th drive gear and bushing are replaced.
^ When the 3rd to 6th synchro ring assemblies are replaced.
^ When the 3rd-4th hub and sleeve assemblies are replaced.
^ When the 5th-6th hub and sleeve assemblies are replaced.
1) Insert the main shaft assembly into the adapter plate.
2) Set the height gauge to the adapter plate. Lower the height gauge indicator to the upper face of the snap ring groove or the upper side of the main rear bearing. Set to 0 point.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ The height gauge will be set on the adapter plate during the measurement. Use a scraper to remove any gasket material remaining on the end face.
^ During measurement, do not place the height gauge in the shaded area shown in the figure.
3) Use a height gauge to measure "D1" and "D2" as shown in the figure.
(1) Shift the 5th-6th sleeve to the 6th main gear side, push up on the stopper, and measure "D2".
NOTE:
^ Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 6th side end surface of the sleeve.
^ The measurement is to be performed with 2 persons, while holding the sleeve straight.
^ Turn approximately 72° at a time, and measure the sleeve in 5 locations. Round off the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
(2) Set the height gauge indicator upside down.
(3) Shift the 5th-6th sleeve to the 5th main gear side, push down to the stopper, and measure "D1".
NOTE:
^ Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the 5th side end surface of the sleeve.
^ Turn approximately 72° at a time, and measure the sleeve in 5 locations. Round off the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
4) According to both of the measurements, calculate the neutral position of the 5th-6th sleeve. From the following calculation, select a fork rod which matches the calculated value.
Calculation: T = (D1 + D2) / 2
T: 5th-6th sleeve center position
C1: Measured length from the shaft rear bearing snap ring groove to the sleeve groove end, when shifted to 5th gear [Measured value +55 mm (2.17 in)]
D2: Measured length from the main shaft rear bearing snap ring groove to the sleeve groove end, when shifted to 6th gear
NOTE: Attach the indicator upside down in comparison to the setting procedures for the 0 point. Add d1 [Numerical value: 55 mm (2.17 in) from the figure below to "D1", and measure "D1".
REVERSE FORK ROD SELECTION
NOTE: In the following conditions, perform the procedures below.
^ When the reverse idler gear is replaced.
^ When the reverse idler gear No. 2 is replaced.
^ When the adapter plate is replaced.
^ When the base is replaced.
1) Insert the reverse idler gear assembly into the adapter plate.
2) Tighten the base COMPL attachment bolts.
3) Set the height gauge to the adapter plate. Lower the height gauge indicator to the mating surface of the adapter plate and case, and set to 0 points.
ST 18853AA000 HEIGHT GAUGE
NOTE:
^ The adapter plate will be the base point for the measurement. Use a scraper to remove any gasket material remaining on the end face.
^ During measurement, do not place the height gauge in the shaded area shown in the figure.
4) Press fit the reverse sleeve to the reverse idler gear No. 2, and measure "T".
NOTE:
^ Set the height gauge indicator near the measurement target, and lock dial (1) as shown in the figure. Turn dial (2), and set the indicator to the end face of the reverse sleeve side.
^ Turn approximately 72° at a time, and measure the sleeve in 5 locations. Round off the 2 highest and 2 lowest measurement values. The remaining center value is used as the measurement value.
5) Calculate the neutral position of the reverse sleeve according to the measurement. From the following calculation, select a fork rod which matches the calculated value.
Calculation: T + 4.8 mm (0.189 in)
