Suzuki SFV650 - 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 and Installation .............. 5B-3
Transmission Construction.................................. 5B-5
Countershaft Gear / Driveshaft Gear
Disassembly and Assembly ..............................5B-6
Transmission Related Parts Inspection...............5B-8
Transmission Oil Seal / Bearing Inspection ........5B-9
Transmission Oil Seal / Bearing Removal and
Installation.......................................................5B-10
Gear Position Switch Inspection .......................5B-12
Gear Position Switch Removal and
Installation.......................................................5B-12
Gearshift Lever Construction ............................ 5B-13
Gearshift Lever Removal and Installation .........5B-13
Gearshift Lever Height Inspection and
Adjustment ......................................................5B-13
Gearshift Shaft / Gearshift Cam Plate
Components....................................................5B-14
Gearshift Construction ......................................5B-14
Gearshift Shaft / Gearshift Cam Plate
Removal and Installation................................. 5B-14
Gearshift Linkage Inspection ............................5B-17
Gearshift Shaft Oil Seal Removal and
Installation.......................................................5B-17
Specifications.....................................................5B-18
Service Data .....................................................5B-18
Tightening Torque Specifications......................5B-18
Special Tools and Equipment ...........................5B-19
Recommended Service Material .......................5B-19
Special Tool ......................................................5B-19
Clutch ....................................................... 5C-1
Precautions...........................................................5C-1
Precautions for Clutch System............................5C-1
Diagnostic Information and Procedures............5C-1
Clutch System Symptom Diagnosis ....................5C-1
Repair Instructions ..............................................5C-2
Clutch Lever Position Switch Inspection .............5C-2
Clutch Cable Inspection and Adjustment ............5C-2
Clutch Cable Removal and Installation ...............5C-2
Clutch Lever Components...................................5C-3
Clutch Lever Removal and Installation................5C-4
Clutch Push Rod (Left) / Clutch Release
Camshaft Removal and Installation ..................5C-4
Clutch Push Rod (Left) Inspection ......................5C-5
Clutch Components.............................................5C-6
Clutch Removal...................................................5C-7
Clutch Installation................................................5C-9
Clutch Parts Inspection .....................................5C-13
Primary Drive Gear Removal and Installation ...5C-14
Primary Drive Gear Inspection ..........................5C-15
Primary Drive Gear Disassembly and
Assembly.........................................................5C-15
Specifications.....................................................5C-16
Service Data......................................................5C-16
Tightening Torque Specifications......................5C-17
Special Tools and Equipment ...........................5C-17
Recommended Service Material .......................5C-17
Special Tool ......................................................5C-17