wsm L503 Workshop Manual page 261

L3130 · L3430 · L3830 · L4630 · L5030, WSM
(B) Synchronized Gear
Clearance between Shift Fork and Shifter Groove
1. Measure the width of shift fork.
2. Measure the shifter groove width, and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace them.
Factory
spec.
Clearance between shift
fork and shifter groove
Allowable
limit
Checking Contact between Coupling and Shifter
1. Check to see if there is flaw or wear on the spline of the coupling
and shifter, and the key groove on the coupling.
2. Engage the shifter with the coupling, and check that they slide
smoothly.
3. Similarly, check that there is any flaw or wear on the gear splines.
4. If there is any defect, replace them.
Flaw on Synchronizer Key and Spring
1. Check the projection in the center of the synchronizer key for
wear.
2. Check the spring for fatigue or wear on the area where the spring
contacts with the keys.
3. If there is any defect, replace them.
Side Clearance between Synchronizer Ring and Gear
(In Contact)
1. Press the synchronizer ring against the tapered portion of the
gear, and measure the side clearance.
2. Apply thin film of red lead to the tapered portion, press the ring
against it by hand, rub them together a few times, and check the
contact.
3. Check the tooth surface and key grooves of the ring for wear.
4. If the side clearance exceeds the allowable limit or if there is any
defect, replace the synchronizer ring.
Side clearance Allowable limit
Contact condition of
Allowable limit
tapered portion
3-S44
TRANSMISSION
Shuttle 0.20 to 0.45 mm
F-R 0.0079 to 0.0177 in.
0.15 to 0.40 mm
Other
0.0059 to 0.0157 in.
Shuttle 0.80 mm
F-R 0.031 in.
0.80 mm
Other
0.031 in.
W1020704
W1020860
W1021026
0.35 mm
0.0138 in.
More than 80 %
W1026696
KiSC issued 02, 2007 A