Transmission Related Parts Inspection; Gearshift Fork To Groove Clearance; Gearshift Fork Groove Width; Gearshift Fork Thickness - Suzuki GSX-R1000 Service Manual

Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys
5B-12 Manual Transmission:
• When installing the gear bushing onto the
countershaft, align the shaft oil hole "A" with the
bushing oil hole "B".

Transmission Related Parts Inspection

Refer to "Transmission Removal" (Page 5B-3),
"Transmission Installation" (Page 5B-5) and
"Countershaft Gear / Driveshaft Gear Disassembly and
Assembly" (Page 5B-10).

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 the 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)
email: info@motomatrix.co.uk / www.motomatrix.co.uk
"A"
"B"
I947H1520067-01
B947H15206006
(A)
I649G1520056-03

Gearshift Fork Groove Width

Measure the gearshift fork groove width using the
vernier calipers.
Special tool
(A): 09900–20102 (Vernier calipers (200 mm))
Gearshift fork groove width
Standard: 5.0 – 5.1 mm (0.197 – 0.201 in)

Gearshift Fork Thickness

Measure the gearshift fork thickness using the vernier
calipers.
Special tool
(A): 09900–20102 (Vernier calipers (200 mm))
Gearshift fork thickness
Standard: 4.8 – 4.9 mm (0.189 – 0.193 in)
(A)
I649G1520057-03
(A)
I649G1520058-03