1. Check the shift shaft and shift rod for damage. Replace if damaged.
2. Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
3. Inspect the clearance between 1st, 2nd driven gear and reverse driven gear. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a) and (b):
9.5 mm (0.374 in)
|
(A) |
1st driven gear |
|
(B) |
Reverse driven gear |
|
(C) |
2nd driven gear |
|
1st-2nd shifter fork | ||
|
Part number |
Mark |
Remarks |
|
32804AA060 |
1 |
0.2 mm on 1st gear Near (0.008 in) |
|
32804AA070 |
— |
Standard |
|
32804AA080 |
3 |
0.2 mm on 2nd gear Near (0.008 in) |
4. Inspect the clearance between the 3rd, 4th drive gear and the coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a) and (b):
9.3 mm (0.366 in)
|
(A) |
3rd drive gear |
|
(B) |
Coupling sleeve |
|
(C) |
4th drive gear |
|
3rd-4th shifter fork | ||
|
Part number |
Mark |
Remarks |
|
32810AA061 |
1 |
0.2 mm on 4th gear Near (0.008 in) |
|
32810AA071 |
— |
Standard |
|
32810AA101 |
3 |
0.2 mm on 3rd gear Near (0.008 in) |
5. Inspect the clearance between 5th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a):
9.3 mm (0.366 in)
|
(A) |
5th drive gear |
|
(B) |
Coupling sleeve |
|
5th shifter fork (non-turbo) & identification paint (pink) | ||
|
Part number |
Mark |
Remarks |
|
32812AA201 |
7 |
Approaches 5th gear by 0.2 mm (0.008 in). |
|
32812AA211 |
— |
Standard |
|
32812AA221 |
9 |
Moves away from 5th gear by 0.2 mm (0.008 in). |
|
5th shifter fork (turbo) & identification paint (blue) | ||
|
Part number |
Mark |
Remarks |
|
32812AA231 |
7 |
Approaches 5th gear by 0.2 mm (0.008 in). |
|
32812AA241 |
— |
Standard |
|
32812AA251 |
9 |
Moves away from 5th gear by 0.2 mm (0.008 in). |
6. Inspect the rod end clearances (A) and (B). If any clearance is not within specifications, replace the rod or fork as required.
Clearance (A):
1st-2nd — 3rd-4th
0.4 — 1.4 mm (0.016 — 0.055 in)
Clearance (B):
3rd-4th — 5th:
0.5 — 1.3 mm (0.020 — 0.051 in)
