Gear Position Switch Inspection; Gear Position Switch Removal And Installation - Suzuki 2005 GSF1200 Service Manual

Gearshift Fork Thickness
Measure the gearshift fork thickness using the vernier
calipers.
Special tool
(A): 09900–20102 (Vernire calipers)
Gearshift fork thickness
Standard (No.1, No.2 & No.3): 4.80 – 4.90 mm (0.189 –
0.193 in)
Gearshift Cam Bearing
Inspect the gearshift cam bearings, left and right for
abnormal noise and smooth rotation.
Replace the bearing if there is anything unusual.

Gear Position Switch Inspection

1) Remove the seat. Refer to "Exterior Parts Removal
and Installation: in Section 9D".
2) Disconnect the gear position switch coupler.
3) Check the continuity between Blue and Black/White
lead wires with the transmission in "NEUTRAL".
!
When disconnecting and connecting the gear
position switch coupler, make sure to turn off
the ignition switch, or electronic parts may
get damaged.
Special tool
Tester knob indication
Continuity test (
(A)
I649G1520058-02
ON (Neutral)
OFF (Except neutral)
4) Connect the gear position switch coupler to the
wiring harness.
5) Install the seat. Refer to "Exterior Parts Removal and
Installation: in Section 9D".
I649G1520059-01

Gear Position Switch Removal and Installation

Refer to "Electrical Components Location: in Section
B649G15206033 0A".
Refer to "Wiring Harness Routing Diagram: in Section
9A".
Removal
1) Remove the seat. Refer to "Exterior Parts Removal
and Installation: in Section 9D".
2) Remove the left flame cover. Refer to "Exterior Parts
Removal and Installation: in Section 9D".
3) Remove the engine sprocket cover. Refer to "Engine
Sprocket Removal and Installation: in Section 3A".
I649G1190030-02
Manual Transmission:
CAUTION
: 09900–25008 (Multi-circuit tester set)
)
Bl
G/Bl
BI
5B-17
R/B
B/W
I649G1190048-01
B/W
I649G1190045-02
B649G15206034