Transfer Inspection

Reference: TRANSFER ASSEMBLY DISMOUNTING AND REMOUNTING 

Reference: TRANSFER DISASSEMBLY 

• Check each ball bearing for smooth rotation. If found abnormal, replace.
  Fig 1: Checking Ball Bearing

  Courtesy of SUZUKI OF AMERICA CORP.
• Check needle bearing and bearing contacting surface for damage. Replace as required.
• Check gear tooth surface and shift mechanism in the same manner as with transmission. Correct or replace as necessary.
• Check each spring for distortion or breakage and change it with new one as necessary.

  Especially for locating springs (1), measure each free length and replace if it is below service limit.

  Locating spring free length "a" 

  Standard: 19.5 mm (0.768 in.) 

  Service limit: 18.0 mm (0.709 in.) 

  Fig 2: Measuring Springs Free Length

  Courtesy of SUZUKI OF AMERICA CORP.
• Check drive chain and sprockets for abnormal wear or damage. Replace as required.
• Check oil seal for leakage and its lip for excessive hardness. If either is found, replace. Also, check corresponding surface of shaft where oil seal lip contacts. Correct or replace as necessary.
• Check gear tooth surface of speedometer drive gear. Replace if it is damaged.
• Put synchronizer outer ring (1), inner ring (3) center cone (2) and inner ring (3) together and then measure the step difference between outer ring (1) and inner ring (3). And also check key slot or boss width "c" in synchronizer outer ring (1) and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.

  Difference "b" between outer ring and inner ring 

  Standard: 1.0 - 1.4 mm (0.039 - 0.055 in.) 

  Service limit: 0.5 mm (0.020 in.) 

  Key slot or boss width "c" in synchronizer outer ring 

  Standard: 10.1 mm (0.398 in.) 

  Service limit: 10.4 mm (0.409 in.) 

  Fig 3: Identifying Clearance Between Outer Ring & Inner Ring, & Key Slot Or Boss Width In Synchronizer Outer Ring

  Courtesy of SUZUKI OF AMERICA CORP.
• Check chamfered part of each sleeve (1) for damage and excessive wear, and replace as necessary.
• Using feeler gauge, check clearance between sleeve (1) and shift fork (2) and replace parts if necessary.

  Clearance "d" between sleeve and shift fork 

  Maximum 1.0 mm (0.039 in.) 

  Fig 4: Identifying Clearance Between Sleeve And Shift Fork

  Courtesy of SUZUKI OF AMERICA CORP.
• Check splined portions and replace parts if excessive wear is found.