Suzuki LS650 Savage - Mainshaft Assembly

TRANSMISSION AND GEARSHIfT MECHANISMS
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14. Make sure that all gears and bu shings slide
smoot hl y on the mainshaft splines.
NOTE
It is recommended that all eirelips be
replaced l'l'ery rime Ihe transmission is
disasSt'mb/ed to ensure proper gear
alignmelll. When installing ei re/ips,
slide them 0 1110 the shaft with the
rounded side going on fir s t. This will
position the sha'1) silJe oil/ward to take
Ihe gear thrust correctly. Do not
expmuJ a cire/ip more than necessary
10 slide it ol'er the shaft.
15. In spect the drive pulley splines (A. Figure 49).
the gcar splines (8. Figure 49). the speedometer
dr i ve gcar (C. Figure 49) and the circl ip grooves
of the mainshaft. If any arc damaged. the shaft
must be replaced.
Main s haft Assembly
I. Apply a light coat of clean engine oil to all
sliding surfaces before installing any parts.
2. Install the
circlip ( Figure 50 ).
3. Slide on the 4th gear ( Figur e 51 ).
4. Slide on the splincd washer (Figu re 52). Rotate
the splined washer in either direction to engage the
tangs into the grooves on the transmission shaft
(
Figur e 53).
5. Slide on th e splincd lockwasher ( Figure 54) and
push it on until the tangs go into the open areas
of the splined washer ( Figure 55) and lock the
washer into place.