ENGINE 3-43
GEAR
• Inspect the teeth of gear for wear, scratch or damage.
• Inspect the dock of gear for wear or damage.
• If there are anything unusual, replace them with new ones.
GEARSHIFT FORK TO GROOVE CLEARANCE
• Using a thickness gauge, check the gearshift fork clearance in
the groove of its gear.
• The clearance for each gearshift fork plays an important role in
the smoothness and positiveness of the shifting action.
Shift fork to groove clearance:
Standard: 0.1 – 0.3 mm(0.004 – 0.012 in)
Service Limit: 0.50 mm (0.020 in)
\ 09900-20803: Thickness gauge
• If the clearance checked is noted to exceed the limit specified,
replace the fork or its gear, or both.
GEARSHIFT FORK GROOVE WIDTH
• Measure the gearshift fork groove width using the vernier cali-
pers.
Shift fork groove width:
Standard: 5.0 – 5.1 mm (0.197 – 0.201 in)
\ 09900-20102: Vernier calipers
GEARSHIFT FORK THICKNESS
• Measure the gearshift fork thickness using the vernier calipers.
Shift fork thickness:
Standard: 4.8 – 4.9 mm (0.189 – 0.193 in)
\ 09900-20102: Vernier calipers
REASSEMBLY
Assemble the countershaft and driveshaft in the reverse order of
disassembly. Pay attention to the following points:
NOTE:
* Rotate the bearings by hand to inspect for smooth rotation. Re-
place the bearings if there is anything unusual.
* Before installing the gears, apply engine oil to the driveshaft
and countershaft.
* Before installing the oil seal, apply grease to oil seal.
X 99000-25010: SUZUKI SUPER GREASE “A”
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