ПЕРВИЧНЫЙ ВАЛ - ПОВТОРНАЯ СБОРКА

Using SST and a press, install the input shaft front bearing to the input shaft.

• SST
• 09950-00020

• УКАЗАНИЕ:

• Make sure that the groove of the bearing faces the correct direction as shown in the illustration.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-31026	A	2.65 to 2.70 mm (0.1043 to 0.1063 in.)
  90520-31027	B	2.70 to 2.75 mm (0.1063 to 0.1083 in.)
  90520-31028	C	2.75 to 2.80 mm (0.1083 to 0.1102 in.)
  90520-31029	D	2.80 to 2.85 mm (0.1102 to 0.1122 in.)
  90520-31030	E	2.85 to 2.90 mm (0.1122 to 0.1142 in.)
  90520-31031	F	2.90 to 2.95 mm (0.1142 to 0.1161 in.)

Using a brass bar and hammer, install the snap ring to the input shaft.

Apply a light coat of gear oil to the sleeve and hub.

Install the No. 2 clutch hub to the clutch hub sleeve.

Install one of the balls to each shifting key.

Install one of the springs to each shifting key.

Install the shifting keys with balls and springs to the No. 2 clutch hub.

• УКАЗАНИЕ:

• Make sure that the No. 2 clutch hub faces the correct direction as shown in the illustration.

• ПРИМЕЧАНИЕ:

• Be careful to prevent the balls from flying off.

Apply a light coat of gear oil to the sleeve and hub.

Install the No. 3 clutch hub to the clutch hub sleeve.

Install one of the balls to each shifting key.

Install one of the springs to each shifting key.

Install the shifting keys with balls and springs to the No. 3 clutch hub.

• УКАЗАНИЕ:

• Make sure that the No. 2 clutch hub faces the correct direction as shown in the illustration.

• ПРИМЕЧАНИЕ:

• Be careful to prevent the balls from flying off.

Coat the 4th gear needle roller bearing with gear oil, and then install it to the input shaft.

Coat the 4th gear and No. 3 synchronizer ring with gear oil, and then install them to the input shaft.

Using SST and a press, install the No. 2 clutch hub to the input shaft.

• SST
• 09308-14010

• УКАЗАНИЕ:

• Align the groove of the clutch hub of the synchronizer ring with the protrusion.

Check that the gear and synchronizer ring move smoothly.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-42012	A	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
  90520-42013	B	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
  90520-42014	C	1.90 to 1.95 mm (0.0748 to 0.0767 in.)
  90520-42015	D	1.95 to 2.00 mm (0.0767 to 0.0787 in.)
  90520-42016	E	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
  90520-42017	F	2.05 to 2.10 mm (0.0807 to 0.0826 in.)
  90520-42018	G	2.10 to 2.15 mm (0.0826 to 0.0846 in.)

Using a snap ring expander, install the snap ring to the input shaft.

Coat the No. 2 synchronizer ring set with gear oil, and then install it to the input shaft.

Coat the spacer with gear oil and install it to the input shaft.

Coat the 3rd gear needle roller bearing with gear oil and install it to the input shaft.

Install the straight pin to the input shaft.

Coat the 3rd gear with gear oil and install it to the input shaft.

Coat the 3rd gear thrust washer with gear oil and install it to the input shaft.

• УКАЗАНИЕ:

• Align the groove of the gear thrust washer with the straight pin.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-39026	A	2.07 to 2.12 mm (0.0815 to 0.0835 in.)
  90520-39027	B	2.12 to 2.17 mm (0.0835 to 0.0854 in.)
  90520-39028	C	2.17 to 2.22 mm (0.0854 to 0.0874 in.)
  90520-39029	D	2.22 to 2.27 mm (0.0874 to 0.0894 in.)
  90520-39030	E	2.27 to 2.32 mm (0.0894 to 0.0913 in.)
  90520-39031	F	2.32 to 2.37 mm (0.0913 to 0.0933 in.)

Using a snap ring expander, install the snap ring to the input shaft.

Coat the spacer with gear oil and install it to the input shaft.

Coat the 6th gear needle roller bearing with gear oil and install it to the input shaft.

Install the 6th gear to the input shaft.

Install the synchronizer ring to the input shaft.

Using SST and a press, install the clutch hub to the input shaft.

• SST
• 09309-37010
  09950-00020

Check that the gear and synchronizer ring move smoothly.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-33022	A	2.10 to 2.15 mm (0.0827 to 0.0847 in.)
  90520-33023	B	2.15 to 2.20 mm (0.0847 to 0.0866 in.)
  90520-33024	C	2.20 to 2.25 mm (0.0866 to 0.0886 in.)
  90520-33025	D	2.25 to 2.30 mm (0.0886 to 0.0906 in.)
  90520-33026	E	2.30 to 2.35 mm (0.0906 to 0.0925 in.)
  90520-33027	F	2.35 to 2.40 mm (0.0925 to 0.0945 in.)
  90520-33028	G	2.40 to 2.45 mm (0.0945 to 0.0965 in.)

Using a brass bar and hammer, install the snap ring to the input shaft.

Using a dial indicator, measure the 6th gear thrust clearance.

• Standard clearance:
• 0.20 to 0.49 mm (0.00788 to 0.0193 in.)

If the clearance is outside the specification, replace the gear, spacer or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a feeler gauge, measure the 3rd gear thrust clearance.

• Standard clearance:
• 0.09 to 0.52 mm (0.00355 to 0.0205 in.)

If the clearance is outside the specification, replace the gear, thrust washer, clutch hub or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 4th gear thrust clearance.

• Standard clearance:
• 0.12 to 0.38 mm (0.00473 to 0.0150 in.)

If the clearance is outside the specification, replace the gear, clutch hub or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 6th gear radial clearance.

• Standard clearance:
• 0.015 to 0.065 mm (0.000591 to 0.00255 in.)

If the clearance is outside the specification, replace the gear, needle roller bearing or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 3rd gear radial clearance.

• Standard clearance:
• 0.015 to 0.067 mm (0.000591 to 0.00263 in.)

If the clearance is outside the specification, replace the gear, needle roller bearing or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 4th gear radial clearance.

• Standard clearance:
• 0.015 to 0.051 mm (0.000591 to 0.00200 in.)

If the clearance is outside the specification, replace the gear, needle roller bearing or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.