Gearshift Fork-Groove Clearance; Transmission Reassembly - Suzuki DR350 Service Manual

3·29 ENGINE
GEARSHIFT FORK-GROOVE CLEARANCE
Using a thickness gauge. c heck the shifting fork clearance
in the groove o f its gear.
The clearance for each of the th ree shi fting forks plays an
improtant role in the sm oothness and posi tiveness o f shih·
ing action .
Shift fork -Groove clearance
Standard : 0 . ' - 0 .3 mm (0 .004 - 0 .012 in'
Service Limit : 0 .5 mm (0 .020 in)
If the clea rance c hecked is noted to exceed th e limit speci·
fied . repla ce the fork or its gear , or both .
Shift fork groove width
Stand ard : 5 .0 - 5 .1 mm (0 ,197 - 0 .200 in)
Shift fork thick ne ss
Standard : 4 .8 - 4.9 mm (0 .189 - 0 .193 in)
09900-20803 : Thickness gauge
09900 -20101 : V ernier calipers
REASSEMBLY
Checking clearance
Checking groove width
Chicking t hickness
Assemble the countershaft and driveshaft. in t he reverse order of disassembly . Pay attention to fol -
lowing points:
NOTE:
In reassembling the transmission. atten tion must be given to the locations and posi tions of washers
and circlips. The c ross sectional view given here will serve as
8
reference for correc tly mounting
the gears, washers and eirclips.
CAUTION:
• Never reuse a circlip . After a circlip has been removed from a shaft, the removed circlip should
be discarded and a new circllp must be installed .
• When installing a new circlip. care must be taken not to expand the end gap larger than required
to slip the c irclip over the shaft.
• After installing a circlip , always insure that it is completely seated in its groove and securely fitted.
NOTE:
Before installing the gears, coa t lightly moly paste o r engine oil to the drivesh8ft and counrershaft.
99000 -25140 :
SUZUKI MOLY PASTE