Suzuki LS650 Savage - Countershaft Assembly

TR ANS MI SS IO N AN D GEARSHIFT MECHANISMS 181
@
®
,.
Countershaft Assembly
I. Apply a li ght coat of clean engine oi l 10 all
sl
idi ng s urf aces before installing any pa rtS.
2. Slide on the 3rd gear bush in g (Fig ur e 69) and
in sta ll t he 3rd gear ( Figur e 70 ).
3. Slide on th e thrust wa sh er ( Fi gure 71 ).
4. Insta ll th e circlip ( Fi g ur e 72 ). Make sure it is
correc tl y se ated in th e co unt ershaft gr oove ( Fi g ur e
73).
5. Slide on th e 2n d gear ( Fi g ur e 74 ).
6. In sta ll th e circiip (Fig ur e 75 ). Make sure it is
correc
tl y seated in th e cou nte rsh aft groove.
CAUTION
Th ere ar e 2 sp/ in ed wa shers II sed on
this shaft. On e has 3 dogs ami is thin.
Th e other has 6 dogs and ;s thick.
Th eu spli ned washers must be
in staffed in the correct position or
damage to the t ransmission
co mponents will resu lt.
7. Sl id e on the thin 3-dog s pl ined was her (Fig ur e
76
).
8. Slide on the 4th gear (Figure 77 ).
9. S li de on th e thick 6-<1o g s pli ned wa sher ( Fi gure
78).
10. Ins ta ll t he circiip (F igur e 79 ). Make sure it is
corr ec tl y seated in th e co un t er shaft groove.
11 . Refer to Fig ur e 80 for correct pl aceme nt of a ll
gears. Make sure a ll circlips are se at ed corr ec tl y
in th e countershaft groove s.
12 . Make sure each gear en gag es prope rl y to th e
ad
jo in in g g ea r where app li cabl e.
®