Transmission Inspection - Suzuki RM-Z250 Service Manual

TRANSMISSION INSPECTION

• Inspect the gear teeth, dogs, and gearshift grooves for abnor-
mal wear and damage.
• Inspect the bushings and splines for abnormal wear and dis-
coloration.
• If necessary, replace defective parts with a new one.
• Inspect the gearshift cam groove for abnormal wear and dam-
age.
• If any defects are found, replace the gearshift cam with a new
one.
• Inspect the gearshift forks and shaft for wear and damage.
• If any defects are found, replace the gearshift fork or shaft.
• Measure the gearshift fork to groove clearance with a thick-
ness gauge.
• If the clearance checked is noted to exceed the limit, replace
the fork or dog.
 Gearshift fork to groove clearance
Service Limit: 0.50 mm (0.020 in)
 09900-20803: Thickness gauge
• Measure the gearshift fork thickness with a vernier calipers.
 Gearshift fork thickness
Standard: 4.80 – 4.90 mm (0.189 – 0.193 in)
 09900-20101: Vernier calipers
TRANSMISSION AND CRANKSHAFT 10-7