Disassembly/Assembly
Before assembly, wipe all parts with solvent, dry them and apply lubricant to the contact areas.
1. 3rd/4th gear fork
2. 1ST/2nd GEAR SHIFT FORK
3. DRINK, 5 mm, 07GAD-PG20100
4. SPRING PIN 5x22 mm. Replace
5. 5th GEAR/REVERSE SHIFT PART
6. 5th GEAR/REVERSE SHIFT FORK
Clearance check
Note: Synchronizer cage and hub must be replaced as an assembly.
1. Measure the clearance between each shift fork and the corresponding synchronizer sleeve.
- Standard (new): 0.35-0.65mm
- Limit; 1.00 mm
2. If the clearances exceed the specified limit, measure the thickness of the shift fork pins.
If the thickness of the shift fork pins is less than normal, replace the shift fork with a new one.
If the thickness of the shift fork fingers is within the normal range, replace the synchronizer sleeve with a new one.
3. Measure a backlash between a shift fork and a leader And a gear change.
- Standard: 0.2-0.5mm
- Limit: 0.6mm
4. If the gap exceeds the specified limit, measure the width of the gear change lever A.
- Standard: 12.9-13.0mm
If the width of shifter A is less than normal, replace the shifter A with a new one.
If the width of shifter A is within limits, replace the shift fork or shift part with new ones.