Gear Shift Shaft and Fork Inspection

Reference: MANUAL TRANSAXLE ASSEMBLY DISASSEMBLY AND REASSEMBLY 

Reference: GEAR SHIFT SHAFT AND FORK COMPONENTS 

1. Using feeler gauge, check clearance between fork (1) and sleeve (2) and replace those parts if it exceeds limit.
   NOTE: For correct judgement of parts replacement, carefully inspect contact portion of fork and sleeve.

   Clearance "a" between fork and sleeve 

   Standard: 0.05 - 0.35 mm (0.002 - 0.013 in.) (Low speed) 

   Limit: 0.4 mm (0.016 in.) 

   Standard: 0.05 - 0.35 mm (0.002 - 0.013 in.) (High speed) 

   Limit: 0.4 mm (0.016 in.) 

   Standard: 0.05 - 0.35 mm (0.002 - 0.013 in.) (5th & 6th gear) 

   Limit: 0.4 mm (0.016 in.) 

   Standard: 0.05 - 0.25 mm (0.002 - 0.010 in.) (Reverse gear) 

   Limit: 0.4 mm (0.016 in.) 

   Fig 1: Checking Clearance Between Fork And Sleeve

   Courtesy of SUZUKI OF AMERICA CORP.
2. Insert each gear shift shaft into case and check that it moves smoothly. If it doesn't, correct using oilstone, reamer or the like.