Suzuki sq-416-420-625 Service Manual page 497

7D-2 TRANSFER
DIAGNOSIS TABLE
Before attempting to repair the transfer or related components for any reason other than mechanical failure, the
condition and probable causes should be identified.
Transfer failures are revealed by shifting difficulties such as excessive shifting effort, gear clash, or gear grinding.
When any of these conditions occur, the following inspections should be made before disassembling the transfer.
1) Check transfer oil level for insufficient or incorrect oil. Refer to "Transfer and Differential Oil Inspection and
Change" in SECTION 0B "MAINTENANCE AND LUBRICATION".
2) Check transfer mountings for wear or looseness.
3) Check gearshift control lever for distortion or excessive wear.
After performing the above inspections, refer to following diagnosis table.
Condition
Gear slipping out of mesh
Gears refusing to disengage
Hard shifting
Noise
DIAGNOSIS
Possible Cause
D Worn shift fork shaft
D Worn shift fork or synchronizer sleeve
D Weak or damaged locating spring
D Worn bearings on output rear shaft
D Worn chamfered tooth on sleeve or gear
D Missing or disengagement of circlip(s)
D Weakened or broken synchronizer spring
D Distorted shift shaft or shift fork
D Weakened front drive shift shaft spring
D Distorted or mispositioned front drive shift
shaft circlip and washer
D Inadequate or insufficient lubricant
D Worn synchronizer ring
D Worn chamfered tooth on sleeve or gear
D Distorted shift shaft
D Inadequate or insufficient lubricant
D Damaged or worn bearing(s)
D Damaged or worn gear(s)
D Damaged or worn synchronizer ring
D Damaged or worn chamfered tooth on
sleeve or gear
Correction
Replace
Replace
Replace
Replace
Replace sleeve and gear
Install
Replace
Replace
Replace
Replace
Replenish
Replace
Replace sleeve and gear
Replace
Replenish
Replace
Replace
Replace
Replace