REPAIR INSTRUCTIONS

Inspection Of Parts

Inspection and Cleaning

Thoroughly clean the cases, covers and all other parts of the transmission. Remove all grease, oil and foreign matter, using a suitable safety solvent. Dry the parts with moisture-free compressed air.

Bearings

Soak bearings in fresh clean solvent to loosen all hardened grease and foreign matter, until the bearings are clean. Blow them dry with filtered, moisture-free compressed air.

Clean the bearings that are satisfactory for installation. Wrap the bearings in clean, lint-free cloth and store for assembly.

Gears

Replace all gears having teeth that show signs of abrasive wear, scratching (except normal manufacturing tool marks), ridging, scoring, surface fatigue, pitting, spalling, corrosive wear, digging in or cracking. Gears should always be inspected using magnaflux (or similar method) for cracks that would not otherwise be detected.

Shifter Forks, Sliding Clutches and Shift Rails

Do not spin the bearings with compressed air. Doing so can damage the bearings.

Inspect each bearing for flaking, cracks, fractures, cavities, indentations, measurable wear, brinelling, fretting, corrosion, nicking, cage wear or deformation and other damage. If any of these conditions are present, the bearing should be replaced.

Apply a light coat of fresh, clean, specified gear oil to the bearings. (Refer to Recommended SAE Grade Gear Oil in “Transmission Specifications and Capacities” on page 237.) Turn the races and bearings slowly by hand to be sure they move freely and are smooth. If there is resistance to movement, or if the bearing cones or cups feel rough, replace the bearings.

Replace forks and/or sliding clutches when the side clearance (A) between the fork (2) and sliding clutch (1) groove exceeds the specified limit (refer to “TRANSMISSION SPECIFICATIONS” on page 224). 301

If a bearing cone or cup needs replacement, a complete new assembly, including cup and mating cone, is required.

Do not remove a new bearing from its packing before time of installation. Never clean protective grease from new bearings.

Do not handle bearings with dirty hands. Rags must be clean and lint free.