Transmission Related Parts Inspection - Suzuki 2005 GSF1200 Service Manual

5B-16 Manual Transmission:
Countershaft Gear Assembly
• Align the bushing oil hole "A" with the shaft oil hole
"B".
"A" "B"
• With the lock washer (1) turned in its groove "C", align
the cutout "D" of the lock washer (1) with the tab "E"
on the lock washer (2).
1
"D"
"C"
CAUTION
!
Install the oil seal as shown in the illustration.
3
1. Left end bearing
2. Oil seal
I649G1520053-01
2
"E"
I649G1520054-02
2
1
4
I649G1520055-01
3. 2nd drive gear
4. Countershaft

Transmission Related Parts Inspection

Refer to "Transmission Removal: ", "Transmission
Installation: " and "Countershaft Gear and Driveshaft
Gear Disassembly: ".
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: 0.10 – 0.30 mm (0.004 – 0.012 in)
Service limit: 0.50 mm (0.020 in)
Gearshift Fork Groove Width
Measure the gearshift fork groove width using the
vernier calipers.
Special tool
(A): 09900–20102 (Vernire calipers)
Gearshift fork groove width
Standard (No.1, No.2 & No.3): 5.00 – 5.10 mm (0.197 –
0.201 in)
B649G15206032
(A)
I649G1520056-02
(A)
I649G1520057-02