Clutch repair Clutch plate thickness Note: Wipe off engine oil from the clutch plates with a clean rag. Measure the thickness of drive and driven plates with a vernier calipers. If each plate is not within the service limit or standard range, replace it with a...
Gearshift cover — disassembly Disassembly Remove the gearshift shaft oil seal 1. Remove the bearing with the special tools. 09921-20210: Bearing remover 09930-30104: Sliding shaft Reassembly Install the bearing 1 and oil seal 2 with the special tool. 09913-70210: Bearing...
Clutch release camshaft — disassembly Disassembly Remove the clutch release arm 1, return spring 2 and washer 3. Pull out the oil seal 4, bearing 5 with the clutch release camshaft 6. Caution: The removed oil seal and bearing must be replaced with new one. Remove the clutch push rod cap...
Gearshift shaft/gearshift arm reassembly Gearshift shaft/gearshift arm disassembly Remove the following parts from the gearshift shaft/gearshift arm. 1. Washer; 2. Snap ring; 3. Gearshift shaft return spring; 4. Gearshift cam drive plate; 5. Plate return spring Gearshift shaft/gearshift...
Transmission installation Install the countershaft assembly on the upper crankcase. Note: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing. Install the driveshaft assembly on the upper crankcase. Note: Align the C-ring with the...
Gear position switch Apply SUZUKI SUPER GREASE "A" to the O-ring. Note: Align the gear position switch pin А with the gearshift cam hole 2. 99000-25010: SUZUKI SUPER GREASE "A" or equivalent Install the gear position switch 3 as shown. Apply THREAD LOCK SUPER to the...
Gearshift — reassembly Install the gearshift cam stopper 1, its bolt 2, washer 3 and return spring 4. Note: Apply a small quantity of THREAD LOCK to the gearshift cam stopper bolt 2 and tighten its to the specified torque. 99000-32050: THREAD LOCK "1342" or equivalent...
Secondary drive gear Change the gear position to the 1st or 2nd. Hold the primary driven gear with the special tool. 09930-44541: Rotor holder Apply a small quantity of THREAD LOCK SUPER to the secondary drive gear bolt and tighten its to the specified torque....
Gearshift cover — reassembly Install the dowel pins and gasket 1. Caution: Use new gasket to prevent oil leakage. Install the gearshift cover and tighten its bolts. Note: Apply grease to the oil seal lip before installing the gearshift cover. 99000-25010: SUZUKI SUPER GREASE...
Secondary driven gear Install the shims 1 onto the secondary driven gear case. ( 4-11 ) Fit the O-ring 2 and apply engine oil. Caution: Use the new O-ring to prevent oil pressure leak. Install the secondary driven gear case 3 with the bolts and then tighten them to the...
Clutch — reassembly Install the needle bearing 1 and spacer 2 onto the countershaft. Apply engine oil to them. Install the primary driven gear assembly 3 onto the countershaft. Install the thrust washer 4. Install the clutch sleeve hub assembly 5 onto the countershaft....
Clutch cover Loosen the lock nut 1 and turn in the release screw 2 to feel resistance. From that position, turn out the release screw 2 1 turn and tighten the lock nut 1 securely by holding the release screw 2. Install the dowel pins and gasket 3. Caution: Use...