3-43 ENGINE
GEAR-SHIFTING FORK CLEARANCE
Using a thickness gauge, check the shifting fork clearance in
the groove of its gear.
The clearance for each of the three shifting forks plays an
important role in the smoothness and positiveness of shifting
action.
If the clearance checked is noted to exceed the limit specified,
replace the fork or its gear, or both.
09900-20803
:
Thickness gauge
09900-20101
:
Vernier calipers
Shift fork - Groove clearance
Standard
:
0.10 - 0.30 mm (0.004 - 0.012 in)
Service Limit
:
0.50 mm (0.020 in)
Shift fork groove width
Standard
No. 1
:
5.50 - 5.60 mm (0.217 - 0.220 in)
No. 2
:
4.50 - 4.60 mm (0.177 - 0.181 in)
Shift fork thickness
Standard
NO.
1 : 5.30 - 5.40 mm (0.209 - 0.213 in)
No. 2
:
4.30 - 4.40 mm (0.169 - 0.173 in)
COUNTERSHAFT AND DRIVESHAFT
REASSEMBLY
Assemble the countershaft and driveshaft, in the reverse order of disassembly. Pay attention to following
points:
NOTE:
Always use new circlips.
NOTE:
Before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft.
99000-25140
:
SUZUKI MOLY PASTE
CAUTION:
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new
circlip must be installed.
When installing a new circlip, care must be taken not to expand the
end
gap larger than required to slip
the circlip over the shaft.
After installing a circlip, always insure that it is completely seated in its groove and securely fitted.
When installing a new circlip, pay attention to the direction
of the circlip. Fit it to the side where the thrust is as shown
in figure.
4
Sharp edg
.-
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