Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully.
1. Bearing
Replace the bearings in the following cases.
• When the bearing balls, outer races and inner races are broken or rusty.
• When the bearing is worn.
• When the bearings fails to turn smoothly or emits noise when rotated after applying gear oil.
• When bearing has other defects.
2. Bushing (each gear)
Replace the bushing in following cases.
• When the sliding surface is damaged or abnormally worn.
• When the inner wall is abnormally worn.
3. Gear
Replace gears in the following cases.
• Replace gear with new part if its tooth surfaces are broken, damaged or excessively worn.
• Correct or replace if the cone that contacts the baulk ring is rough or damaged.
• Repair or replace if the inner surface or end face is damaged.
4. Baulk ring
Replace the baulk rings in the following cases.
• When the inner surface and end face are damaged.
• When the ring inner surface is abnormally or partially worn down.
• When the contact surface of synchronizer ring insert is cracked or abnormally worn.
5. Shifting insert key
Replace the insert key if deformed, excessively worn or defective in any way.
6. Oil seal
Replace the oil seal if the lip is deformed, hardened, worn or defective in any way.
7. O-ring
Replace the O-ring if the sealing face is deformed, hardened, damaged, worn or defective in any way.
8. Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
9. Measure the clearance between the snap ring and ball bearing with a thickness gauge.
Clearance:
0 — 0.12 mm (0 — 0.0047 in)
|
(A) |
Snap ring |
If the measurement is out of specifications, reselect an appropriate snap ring.
|
Snap ring | |
|
Part No. |
Thickness mm (in) |
|
805028050 |
2.48 (0.0976) |
|
805028060 |
2.56 (0.1008) |
|
805028070 |
2.64 (0.1039) |