Suzuki 2005 GSF1200 - Repair Instructions; Transmission Components; Transmission Removal

5B-2 Manual Transmission:
Repair Instructions
Transmission Components
B649G15206029
Transmission Removal
B649G15206027
1) Remove the engine assembly from the frame. Refer
to “Engine Assembly Removal: in Section 1D”.
2) Remove the generator. Refer to “Generator Removal
and Installation: in Section 1J”.
3) Remove the starter motor. Refer to “Starter Motor
Removal and Installation: in Section 1I”.
4) Remove the oil filter. Refer to “Engine Oil and Filter
Replacement: in Section 0B”.
5) Remove the cam chain tensioner. Refer to “Engine
Top Side Disassembly: in Section 1D”.
6) Remove the CKP sensor component parts and
disconnect the oil pressure switch lead wire. Refer to
“CKP Sensor Removal and Installation: in Section
1H” and “CKP Sensor Removal and Installation: in
Section 1H”.
7) Remove the clutch component parts. Refer to
“Clutch Removal: in Section 5C”.
8) Remove the gearshift shaft and gearshift driven
gear. Refer to “Gearshift Shaft / Gearshift Cam
Driven Gear Removal and Installation: ”.
9) Remove the starter clutch component parts. Refer to
“Starter Clutch Removal and Installation: in Section
1I”.
8
9
10
11
7
6
4
1
2
3
5
12
13
13
13
17
16
14
15
I649G1520041-03
1. 1st (Low) driven gear 9. 3rd drive gear 17. Gearshift cam stopper
2. 4th driven gear 10. 5th (Top) drive gear : Apply oil.
3. 3rd driven gear 11. 2nd drive gear : Apply molybdenum oil solution.
4. 5th (Top) driven gear 12. Gearshift fork shaft : Apply grease to oil seal lip.
5. 2nd driven gear 13. Gearshift fork : Apply thread lock to thread part.
6. Driveshaft 14. Gearshift cam : Apply thread lock to thread part.
7. Countershaft/1st (Low) drive gear 15. Gearshift cam stopper plate : Do not reuse.
8. 4th drive gear 16. Gear position switch