Input Shaft: Inspection

1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring.

   Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.

   If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

   Fig 1: Checking Braking Effect Of Synchronizer Ring

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   NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
3. Check again the braking effect of the synchronizer ring.
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance 

Fig 2: Minimum Clearance Specification Table

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If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

Fig 3: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End

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Using a feeler gauge, measure the clearance between the hub sleeve and gear shift fork.

1. Maximum clearance: 0.35 mm (0.014 in.) 

If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.

Fig 4: Measuring Clearance Between Hub Sleeve And Gear Shift Fork

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1. Check the input shaft for wear or damage.
2. Using a micrometer, measure the journal diameter.

Minimum journal diameter: 

Fig 5: Minimum Journal Diameter Specification Chart

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If the journal diameter is less than the minimum, replace the input shaft.

Fig 6: Checking Input Shaft For Wear Or Damage

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1. Maximum runout: 0.03 mm (0.0012 in.) 

If the runout exceeds the maximum, replace the input shaft.

Fig 7: Checking Shaft Runout Using Dial Indicator

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