Suzuki DR 125, Service Manual

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3-38 ENGINE
GEARSHIFT FORKS
Measure the gearshift fork clearance in the groove of its respec-
tive gear using the thickness gauge.
The clearance for each of the two gearshift forks plays an impor-
tant role in the smoothness and positiveness of the shifting
action. Each fork has its prongs fitted into the annular groove
provided in its gear. During operation there is sliding contact
between the fork and gear and, when a shifting action is initi-
ated, the fork pushes the gear axially.
If the clearance is too great, the meshed gears may slip apart.
If the clearance exceeds the specification, replace the fork, its
respective gear or both.
$
Gearshift fork to groove clearance
Service Limit: 0.5 mm (0.02 in)
&
09900-20803: Thickness gauge
$
Gearshift fork groove width
Standard
No.1: 5.0 – 5.1 mm (0.196 – 0.201 in)
No.3: 5.5 – 5.6 mm (0.217 – 0.224 in)
&
09900-20101: Venier calipers
$
Shift fork thickness
Standard
No.1: 4.8 – 4.9 mm (0.189 – 0.193 in)
No.3: 5.3 – 5.4 mm (0.209 – 0.213 in)
PRIMARY DRIVEN GEAR
If the internal damper wears, play is generated between gear
and housing, causing abnormal noise. If the play is extreme,
replace the primary driven gear assembly with a new one.
1
Primary driven gear
2
Damper
3
Clutch housing