Page 1145 of 2493
NJMT0010
SMT626D
1. Before removing transmission case, remove bolts, check
plugs, springs and check balls as shown left.
+Be careful not to lose check balls.
2. Remove transmission case.
SMT017AA
3. Remove PNP switch.
SMT659C
4. Mesh 4th gear, and then remove reverse idler shaft and
reverse idler gear.
SMT660C
5. Pull out retaining pin.
SMT661C
6. Remove reverse lever spring and reverse lock spring from
reverse lever assembly.
DISASSEMBLYRS5F50A
MT-95
Page 1146 of 2493
SMT662C
7. Remove reverse arm shaft while rotating it.
SMT663C
8. Remove reverse lever assembly and check ball.
+Be careful not to lose check ball.
SMT018B
9. Remove 5th & reverse check plug, spring and ball.
+Be careful not to lose check ball.
SMT664C
10. Remove stopper rings and retaining pins from 5th and 3rd &
4th fork rods.
When removing stopper rings. Use snap ring remover and
installer.
11. Remove 5th and 3rd & 4th fork rods. Then remove forks and
brackets.
SMT105C
12. Remove both input and mainshafts with 1st & 2nd fork and fork
rod as a set.
13. Remove final drive assembly.
+Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
DISASSEMBLYRS5F50A
MT-96
Page 1147 of 2493
SMT138A
14. Remove reverse check assembly and check ball.
+Be careful not to lose check ball.
SMT618AA
SMT027A
15. Remove retaining pin and detach the selector.
SMT028A
16. Remove drain plug for convenience in removing retaining pin
which holds striking lever to striking rod.
SMT619AA
17. Remove retaining pin and then withdraw striking lever and
striking rod.
DISASSEMBLYRS5F50A
MT-97
Page 1148 of 2493
SMT121C
Input Shaft and Gears
DISASSEMBLYNJMT00111. Before disassembly, check 3rd, 4th and 5th input gear end
plays.
Gear end play:
Refer to SDS, MT-133.
SMT476C
+If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Check clearance of snap ring
groove. Refer to ªASSEMBLYº, MT-101.
SMT634AA
2. Remove input shaft rear bearing.
SMT205BA
3. Remove 5th & reverse synchronizer and 5th input gear.
SMT474CA
4. Remove thrust washer ring, 4th input gear thrust washers and
4th input gear.
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears
MT-98
Page 1149 of 2493
SMT040A
5. Remove snap ring.
SMT041AA
6. Remove 3rd & 4th synchronizer and 3rd input gear.
SMT042AA
7. Remove input shaft front bearing.
SMT636A
INSPECTIONNJMT0012Input shaft and GearsNJMT0012S01+Check input shaft for cracks, wear or bending.
+Check gears for excessive wear, chips or cracks.
SMT637A
SynchronizerNJMT0012S02+Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
+Check baulk rings for cracks or deformation.
+Check insert springs for wear or deformation.
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont'd)
MT-99
Page 1150 of 2493
SMT140
+Measure clearance between baulk ring and gear (3rd, 4th and
5th).
Clearance between baulk ring and gear:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT516B
+Measure wear of reverse baulk ring.
1. Place reverse baulk ring on Disc and then place reverse syn-
chronizer cone on reverse baulk ring.
+Make sure projection of synchronizer cone is positioned
over the recess on Tool.
2. While holding reverse synchronizer cone against reverse baulk
ring as firmly as possible, measure dimension ªAº with dial
indicator.
Wear limit:
Dimension ªAº 1.2 mm (0.047 in)
3. If dimension ªAº is smaller than the wear limit, replace baulk
ring.
SMT148A
BearingNJMT0012S03+Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT122C
ASSEMBLYNJMT0013
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont'd)
MT-100
Page 1151 of 2493
SMT441C
1. Place inserts in three grooves on coupling sleeve (3rd & 4th
synchronizer).
SMT477C
SMT123C
2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.
+Pay attention to its direction.
4. Select proper snap ring of 3rd & 4th synchronizer hub to mini-
mize clearance of groove, and then install it.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of 3rd & 4th synchronizer hub:
Refer to SDS, MT-134.
SMT442C
5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove.
Then install them and thrust washer ring.
Allowable clearance of groove:
0 - 0.06 mm (0 - 0.0024 in)
4th input gear thrust washer:
Refer to SDS, MT-134.
SMT206B
7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont'd)
MT-101
Page 1152 of 2493
SMT752C
b. Install insert springs with reverse baulk ring onto coupling
sleeve.
+Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.
SMT208B
e. Place reverse synchronizer assembly on 5th input gear.
+Mesh recesses of 5th input gear with projections of
reverse synchronizer cone.
+Put insert spring mounts on reverse baulk ring upon those
on 5th baulk ring.
SMT124C
f. Press on 5th & reverse synchronizer assembly with 5th input
gear.
SMT753CA
8. Install input shaft front and rear bearings.
9. Measure gear end play as a final check. Refer to
ªDISASSEMBLYº, MT-98.
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont'd)
MT-102