Page 2145 of 2267
10. Install spacer and mainshaft adjusting shim onto mainshaft.
11. Select a mainshaft adjusting shim suitable to satisfy the follow-
ing specification of dimension ªLº and install it onto mainshaft.
Specification of dimension ªLº:
151.35 - 151.45 mm (5.9586 - 5.9626 in)
Available mainshaft adjusting shims:
Refer to SDS, MT-91.
12. Position 4th main gear as shown in the figure, and install it onto
mainshaft.
13. Install 4th main gear onto mainshaft.
CAUTION:
Do not reuse 4th main gear.
14. Install 5th gear bushing with its flange surface facing the 4th
main gear side.
SMT711D 3rd main gear
shim
151.35 - 151.45 mm
(5.9586 - 5.9626 in)
Dimension ªLº
SMT713D 5th main gear
3rd main gear
4th main gear
SMT712D 4th main gear
SMT714D 5th gear bush
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-68
Page 2146 of 2267

15. Install 5th needle bearing, 5th main gear, and 5th gear baulk
ring onto mainshaft.
16. Being careful of the following points, install spread spring, shift-
ing insert, and 5th & reverse synchronizer hub onto 5th &
reverse coupling sleeve.
IPay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.
IInstall synchronizer hub with its three grooves facing the front
side (5th main gear side).
CAUTION:
Do not reuse 5th & reverse synchronizer hub.
IInstall 5th & reverse coupling sleeve with its chamfered surface
facing the reverse main gear side.
17. Install 5th & reverse synchronizer hub assembly.
SMT761D Reverse
SMT694D Shifting insert
(3rd & 4th) (5th & reverse)
Flat shape R-shape
Spread spring
Shifting insert
SMT695D Front
SMT716D Reverse
main gear5th main gear
5th & reverse coupling sleeve
SMT715D 5th & reverse
synchronizer
hub assembly
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-69
Page 2147 of 2267
18. Install reverse gear baulk ring.
19. Install reverse gear bushing.
20. Install reverse gear needle bearing.
21. Install sub-gear, sub-gear washer, and snap ring onto reverse
main gear.
CAUTION:
IPay attention to direction of sub-gear washer.
IDo not reuse snap ring.
22. Install reverse main gear assembly onto mainshaft.
23. Select a thrust washer suitable to satisfy the following specifi-
cation of dimension ªMº (as shown in the figure), and install it
onto mainshaft.
Specification of dimension ªMº:
244.20 - 244.30 mm (9.6142 - 9.6181 in)
Available thrust washers:
Refer to SDS, MT-92.
24. Install mainshaft rear bearing.
SMT717D Reverse gear bush
Reverse gear baulk ring
SMT718D Reverse main gear
Sub-gearSub-gear
washer
Reverse
main gear
Sub-gear washer
Snap ring
SMT719D 244.20 - 244.30 mm
(9.6142 - 9.6181 in)
Thrust washer
Dimension ªMº
SMT720D Mainshaft
rear bearing
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-70
Page 2148 of 2267

25. Install mainshaft C-ring.
26. Using feeler gauge, measure the end play of mainshaft rear
bearing, and check if it satisfies the following specification.
End play specification:
0 - 0.06 mm (0 - 0.0024 in)
Available mainshaft C-rings:
Refer to SDS, MT-91.
27. Install C-ring holder.
28. Install snap ring.
29. Measure gear end play as a final check. Refer to, MT-63.
CAUTION:
IDo not reuse snap ring.
Final Drive
PRE-INSPECTIONNCMT0036
ICheck the clearance between side gear and differential case
as follows.
1. Clean final drive assembly sufficiently to prevent side gear
thrust washer, differential case, side gear, and other parts from
sticking by gear oil.
2. Upright the differential case so that the side gear to be mea-
sured faces upward.
3. Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
Clearance between side gear and differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)
4. If not within specification, adjust the clearance by changing
thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
SMT721D Feeler gauge
Mainshaft C-ring
SMT678D C-ring holder
Mainshaft C-ring
SMT677D Snap ring
SMT610AE Dial gauge
SMT685D
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-71
Page 2149 of 2267

DISASSEMBLYNCMT00161. Remove mounting bolts. Then, separate the final gear from
differential case.
2. Make a notch and remove speedometer drive gear using a
scraper or other suitable tool.
IBearing replacer cannot be positioned unless speedom-
eter drive gear is removed.
3. Remove differential side bearing of final gear side.
4. Turn differential case upside down, and remove differential
side bearing of speedometer drive gear side.
5. Remove speedometer stopper.
6. Remove lock pins from pinion mate shaft.
7. Remove pinion mate shaft.
8. Rotate pinion mate gear, and remove pinion mate gear, pinion
mate thrust washer, side gear, and side gear thrust washer
from differential case.
INSPECTIONNCMT0017
Gear, Washer, Shaft and CaseNCMT0017S01
ICheck side gear, side gear thrust washer, pinion mate shaft,
pinion mate gear, pinion mate gear washer, and differential
case.
ICheck washers for wear.
SMT609A Chamfer
SMT840D Puller
Puller
SMT689D
SMT839
SMT083A
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-72
Page 2150 of 2267

BearingNCMT0017S04
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
IWhen replacing tapered roller bearing, replace outer and
inner race as a set.
ASSEMBLYNCMT0018
1. Apply gear oil to sliding area of differential case, each gear,
and thrust washer.
2. Install side gear thrust washer and side gear into differential
case.
3. Position pinion mate gear and pinion mate thrust washer
diagonally, and install them into differential case while rotating.
4. Insert pinion mate shaft into differential case.
5. Upright the differential case so that its side gear to be mea-
sured faces upward.
6. Place preload adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
7. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
Clearance of side gear and differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)
Available differential thrust washers:
Refer to SDS, MT-92.
8. Hammer the retaining pin into pinion mate shaft.
CAUTION:
Do not reuse retaining pin.
SPD715
SMT062A
SMT087A
SMT685D
SMT750D
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-73
Page 2151 of 2267

9. Align and install speedometer drive gear into differential case.
10. Install speedometer stopper.
11. Install differential side bearing.
12. Turn differential case upside down, and install another differ-
ential side bearing on the other side in the same way.
13. Install final gear into differential case. Apply sealant onto
mounting bolts, and tighten them in order as shown in the fig-
ure with specified torque.
Tightening torque:
Refer to MT-48.
Shift Control Components
INSPECTIONNCMT0019
ICheck if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
ItemOne-side wear
specificationSliding width of new part
1st & 2nd0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th & reverse0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
SMT842D Speedometer drive gear
Installation
directionAlignment
position
SMT751D Speedometer
drive gear
SMT752D
SMT801D One-side wear
Sliding width of
new part One-side wear
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-74
Page 2152 of 2267
ICheck if shift check groove of fork rod or 5th & reverse check
groove is worn, or has any other abnormalities.
SMT692D 1st & 2nd fork rod
5th & reverse fork rod
3rd & 4th fork rod
REPAIR FOR COMPONENT PARTSRS5F70A
Shift Control Components (Cont'd)
MT-75