Suzuki Madura GV700GL Service Manual page 84

MOUNTING 2ND DRIVE GEAR
Press 2nd drive gear to a position so that the
stepped surface
®
of the shaft is aligned with the
end surface ®of the second drive gear as indicated.
991 04 . 32030 Thread lock super "1363A"
GEAR-SHIFTING FORK CLEARANCE
Usi~g
a thickness gauge, check the shifting fork
clearance in the groove of its gear.
This clearance for each of the three shifting forks
plays an important role in the smoothness and
positiveness of shifting action. Each fork has its
prongs fitted into the annular groove provided in
its gear. In operation, there is sliding contact
between fork and gear and, when a shifting action
is initiated, the fork pushes the gear axially. Too
much a clearance is, therefore, liable to cause the
meshed gears to slip apart.
If the clearance checked is noted to exceed the
limit specified, replace the fork or its gear, or both.
09900 . 20803 Thickness gauge
Shift fork- groove clearance
Service Limit
No.1 for 5th driven gear
0.50 mm
No.2 for 6th driven gear (0.020 in)
No.3 for 3rd/4th drive gears
Shift forks groove width
Standard
Shift fork thickness
Standard
5.50- 5.60 mm
(0.217- 0.220 in)
5.30 - 5.40 mm
(0.209- 0.213 in)
ENGINE SERVICING 3-54
NOTE:
*
Before mounting 2nd drive gear, apply
THREAD LOCK SUPER "1363A" to its
bore, taking care not to smear 5th drive
gear with "SUPER "1363A".
*
After mounting the 2nd drive gear, check
that 5th drive gear spins smoothly, by
moving it with your fingers.
*
2nd drive gear may be replaced twice
before it becomes necessary to also replace
the countershaft.