Suzuki GSF1250 - Section 5 Transmission; Transaxle

Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions .................................................5-1
Precautions............................................................. 5-1
Precautions for Transmission / Transaxle............. 5-1
Manual Transmission.............................. 5B-1
Diagnostic Information and Procedures............5B-1
Manual Transmission Symptom Diagnosis ......... 5B-1
Repair Instructions ..............................................5B-2
Transmission Components ................................. 5B-2
Transmission Removal........................................ 5B-3
Transmission Installation .................................... 5B-5
Transmission Construction.................................. 5B-8
Countershaft Gear / Driveshaft Gear
Disassembly and Assembly .............................. 5B-9
Transmission Related Parts Inspection.............5B-12
Gear Position (GP) Switch Inspection............... 5B-12
Gear Position (GP) Switch Removal and
Installation....................................................... 5B-12
Gearshift Lever Construction ............................5B-13
Gearshift Lever Removal and Installation .........5B-14
Gearshift Lever Height Inspection and
Adjustment ...................................................... 5B-14
Gearshift Shaft / Gearshift Cam Plate
Components.................................................... 5B-14
Gearshift Construction ...................................... 5B-15
Gearshift Shaft / Gearshift Cam Plate
Removal and Installation................................. 5B-15
Gearshift Linkage Inspection ............................ 5B-18
Gearshift Shaft Oil Seal / Bearing Removal
and Installation................................................ 5B-19
Specifications.....................................................5B-20
Service Data ..................................................... 5B-20
Tightening Torque Specifications......................5B-20
Special Tools and Equipment ...........................5B-21
Recommended Service Material ....................... 5B-21
Special Tool ......................................................5B-21
Clutch ....................................................... 5C-1
Precautions...........................................................5C-1
Precautions for Clutch System............................5C-1
Clutch Fluid (Brake Fluid) Information.................5C-1
Schematic and Routing Diagram........................5C-2
Clutch Hose Routing Diagram.............................5C-2
Diagnostic Information and Procedures............5C-3
Clutch System Symptom Diagnosis ....................5C-3
Repair Instructions ..............................................5C-3
Clutch Lever Position Switch Inspection .............5C-3
Clutch Fluid Level Check ....................................5C-3
Clutch Hose Inspection .......................................5C-3
Air Bleeding from Clutch Fluid Circuit .................5C-4
Clutch Fluid Replacement ...................................5C-4
Clutch Hose Removal and Installation ................5C-5
Clutch Control System Components ...................5C-6
Clutch Master Cylinder Assembly Removal
and Installation ..................................................5C-7
Clutch Master Cylinder / Clutch Lever
Disassembly and Assembly ..............................5C-8
Clutch Master Cylinder Parts Inspection ...........5C-10
Clutch Release Cylinder / Push Rod Removal
and Installation ................................................5C-10
Clutch Push Rod (Left) Inspection ....................5C-11
Clutch Release Cylinder Disassembly and
Assembly.........................................................5C-11
Clutch Release Cylinder Inspection ..................5C-11
Clutch Components...........................................5C-12
Clutch Removal.................................................5C-13
Clutch Installation..............................................5C-14
Clutch Parts Inspection .....................................5C-18
Specifications.....................................................5C-19
Service Data......................................................5C-19
Tightening Torque Specifications......................5C-19
Special Tools and Equipment ...........................5C-20
Recommended Service Material .......................5C-20
Special Tool ......................................................5C-20