Transmission Related Parts Inspection - Suzuki VLR1800 Service Manual

Countershaft
CAUTION
!
Never reuse countershaft bearing (1).
• Install the countershaft bearing (1) to the countershaft
using the hydraulic press.
NOTE
The bearing knock-pin "A" should be
positioned 1st drive gear side.
1
• When installing the gear bushing onto the
countershaft, align the shaft oil hole "B" with the
bushing oil hole "C".
"C"
• Install the oil seal (2).
NOTE
The chamfer side "D" of the oil seal should
face 2nd drive gear side.
"D"
"A"
1
I822H1520035-01
"B"
I822H1520036-02
2
I822H1520037-03
Manual Transmission:

Transmission Related Parts Inspection

Refer to "Transmission Removal (Page 5B-3)",
"Transmission Installation (Page 5B-4)" and
"Countershaft Gear / Driveshaft Gear Disassembly and
Assembly (Page 5B-8)".
Gearshift Fork to Groove Clearance
NOTE
The clearance for each gearshift fork plays
an important role in the smoothness and
positiveness of the shifting action.
Using a thickness gauge, check the gearshift fork
clearance in the groove of its gear.
If the clearance checked is noted to exceed the limit
specified, replace the fork or its gear, or both.
Special tool
(A): 09900–20803 (Thickness gauge)
Gearshift fork to gearshift fork groove clearance
Standard: 0.1 – 0.3 mm (0.004 – 0.012 in)
Service limit: 0.5 mm (0.02 in)
Gearshift Fork Groove Width
Measure the gearshift fork groove width using the
vernier calipers.
Special tool
(A): 09900–20102 (Vernier calipers (1/20 mm,
200 mm))
Gearshift fork groove width
Standard: 5.0 – 5.1 mm (0.197 – 0.201 in)
5B-11
B822H15206006
(A)
I649G1520056-03
(A)
I649G1520057-03