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CRANKCASE/TRANSMISSION
11-8
INSPECTION
Disassemble
the
mainshaft and countershaft.
Check
the gear dogs,
dog
holes and teeth
for abnor-
mal
wear or lack of
lubrication.
Measure
the
1.
0.
of each
gear.
SERVICE
LIMITS:
M5, M6:
28.04 mm
(1.104
in)
C1:
26.04 mm
(1.025
in)
C2, C3, C4: 31.04 mm
(1.222
in)
Check
the shift fork groove of the shifter gear for
excessive wear or damage.
Measure the
0.0.
of each gear bushing.
SERVICE
LIMITS:
M5, M6:
27.94 mm (1.100
in)
C2:
30.95 mm
(1.219
in)
CJ, C4:
30.93 mm (1.218 in)
Measure
the 1.0. of each
gear
bushing.
SERVICE
LIMITS:
M5:
25.03 mm
(0.985 in)
C2:
28.04 mm (1.104 in)
Calculate
t
he
gear-to-bushing
clearance.
STANDARDS:
M5, M6:
0.020- 0.062 mm (0.0008- 0.0024 in)
C2:
0.005- 0.055
mm
(0.0002-
0.0022 in)
C3,
C4:
0.025
-
0.075 mm
(0.0010-
0.0030 in)
Check
the mainshaft
and
countershaft
for abnormal
wear or damage.
Measure the mainshaft
0.0.
at the M5 gear.
SERVICE
LIMIT:
24.95
mm
{0.982 in)
Measure the countershaft
0.0.
at the
C2
gear.
SERVICE
LIMIT:
27.96 mm (1.101
in)
Calculate the
gear
bushi ng-to-shaft
clearance.
STANDARDS:
M5:
0.005- 0.047 mm {0.0002- 0.0019
in)
C2: 0.020-0.054 mm (0.0008
-
0.0021
in)
Turn
the outer race of each bearing with your
f
inger.
The bearings should turn
smoothly
and quietly.
Also check that
t
he bearing
inner
race fits tightly on
the shaft.
Remove
and
discard
the
mainshaft bearing,
if
the
race does not turn smoothly,
quietly,
or fits
loosely
on the mainshaft.
Replace the
countershaft,
collar, and bearing as an
assembly, if the race does not turn smoothly,
qui-
etly, or fits loosely on
the
countershaft.
C2
M5
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