Suzuki LS650 Savage - Page 184

TRANSMISSION AND GEARSHJIT MECHANISMS
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Removal
1. Remove th e engine an d split th e cr an kcase as
described under
Crankcase Disassembly in
Chapter Four.
2. Withdraw th e shirt fo rk sha ft (Figure 38).
3. Remove
th e mainshart shifl fo rk (Figure 39 ).
4.
Rem ove th e countershaft shift fo rk (F igure 40).
5. Removc the shi
ft drum (Figure 41 ).
6. Remove both t
ra ns mi ssion shaft asse mbl ies.
7. In spect th e transmission sha ft assemblies as
described under Tr ansmission Preliminary
In spection in thi s chapter.
Assembly
I. In sta ll th e 2 t ra nsmission asse mbl ies by meshing
th em toge th er in their proper relations hi p to each
o
th er.
2. Insta
ll bo th transmission asse mbl ies i nt o the
le
ft -hand crankcase half (Figure 42).
3. After both assemblies are in sta ll ed, tap on th e
end
of both shafts (Figure 43 ) wi th a pla st ic or so ft -
fa c ed mallet to make sure th ey a re co mpletely
seated.
4. Coat all bearing and sliding surfaces of the shift
drum with engine
or assembly oil.
5. Install the shi
ft drum (Figure 41 ).
6. Install th e co unte rs ha rt shirt fo rk (Figure 40)
into position in it s ge ar .
7.
In sta ll th e mainshaft shift fork (Figure 39) into
position in its gear.
8. Mesh th e shift forks with th e shi ft drum a nd
install th e shirt fork shart (Figure 38). Apply a
liberal coat of engine oil
0010 th e shift fo rk sha ft
and let th e oil run do wn the shaft a nd o nt o th e shi ft
forks.
9. Make sure
th e cam pin fo ll owers are in mesh
with the groo
ve s in th e shi ft drum.
10 . Ma ke su re th e thrust washer (Figure 44) is still
in sta ll ed on th e mainshaft.
NaTE
Th e next procedure is b es t done with
th e aid of a helper as th e transmission
assembli es ar e loose and \1 '01 1 't spin
~ 'ery easil y. Ha ve a helper hold th e
crankcase and sp in th e transmission
s haf t wh Ue you turn the shift d rum
through all of the gears,