Counter Gear Assembly and Reverse Idler Gear

COMPONENTS

DISASSEMBLY OF COUNTER GEAR ASSEMBLY
REMOVE HUB SLEEVE SHIFTING KEYS AND SPRINGS FROM CLUTCH HUB
(a) Using a screwdriver, remove rear side shifting key spring and three keys and hub sleeve from clutch hub.

(b) Using a screwdriver, remove retainer and front side shifting key spring.

INSPECTION OF COUNTER GEAR
1. MEASURE COUNTER FIFTH GEAR OIL CLEARANCE
(a) Install spacer, counter 5th gear and needle roller _ bearing to counter gear.
(b) Using a dial indicator, measure counter 5th gear oil clearance.
Standard clearance:
0.009 - 0.062 mm (0.0004 - 0.0024 in.)
Maximum clearance:
0.15 mm (0.0059 in.)
If the clearance exceeds the limit, replace the counter gear or needle roller bearing or counter 5th gear.

2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter shaft journal.
Minimum diameter:
Part A 26.835 mm (1.0564 in.)
Part B 29.81 mm (1.1736in.)

3. INSPECT SYNCHRONIZER RINGS
(a) Turn the ring and push it in to check the braking action.

(b) Measure the clearance between the synchronizer ring back and the gear spline end.
Standard clearance:
0.7 - 1.7 mm (0.028 - 0.067 in.)
Minimum diameter:
0.5 mm (0.020 in.)
If the clearance is less than the limit, replace the synchronizer ring.

4. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.

REPLACEMENT OF BEARING
1. IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING AND SIDE RACE
(a) Using snap ring pliers, remove the snap ring.
(b) Using a press and SST, press out the bearing.
SST 09950-00020
(c) Check the side race for wear or damage.

(d) If necessary, remove the side race.
^ Using SST and socket wrench, remove the side race.
SST 09950-20017

(e) Using a socket wrench, press in a new bearing, side race and inner race.

(f) Select a snap ring that will allow minimum axial play and install it on the shaft.

2. IF NECESSARY, REPLACE COUNTER GEAR CENTER BEARING
(a) Remove the bearing from the counter gear.
(b) Install a new bearing on the counter gear.
HINT: Engage the roller cages.

(c) Using SST, tap out the bearing outer race.
SST 09608-35014 (09608-06020, 09608-06090)
HINT: The outer race will be installed later, as the transmission is assembled.

ASSEMBLY OF COUNTER GEAR ASSEMBLY

(5-Speed)
INSERT CLUTCH HUB NO.3 INTO HUB SLEEVE
(a) Install clutch hub No.3 and the shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE: Install the key springs positioned so that their end gaps are not in line.

1. MEASURE REVERSE IDLER GEAR OIL CLEARANCE
Using a dial indicator, measure reverse idler gear oil clearance.
Standard clearance:
0.041 - 0.074 mm (0.0016 - 0.0029 in.)
Maximum clearance:
0.194 mm (0.0076 in.)

2. MEASURE CLEARANCE OF REVERSE IDLER GEAR AND SHIFT ARM SHOE
Using a feeler gauge, measure the clearance between the reverse idler gear and shift arm shoe.
Standard clearance:
0.20 - 0.41 mm (0.008 - 0.0161 in.)
Maximum clearance:
0.9 mm (0.0354 in.)