Repair Instructions; Transmission Components; Transmission Removal - Suzuki 2005 GSF1200 Service Manual

5B-2 Manual Transmission:

Transmission Components

1
6
8
9
1. 1st (Low) driven gear
2. 4th driven gear
3. 3rd driven gear
4. 5th (Top) driven gear
5. 2nd driven gear
6. Driveshaft
7. Countershaft/1st (Low) drive gear
8. 4th drive gear

Transmission Removal

1) Remove the engine assembly from the frame. Refer
to "Engine Assembly Removal: in Section 1D".
2) Remove the generator. Refer to "Generator Removal
and Installation: in Section 1J".
3) Remove the starter motor. Refer to "Starter Motor
Removal and Installation: in Section 1I".
4) Remove the oil filter. Refer to "Engine Oil and Filter
Replacement: in Section 0B".
5) Remove the cam chain tensioner. Refer to "Engine
Top Side Disassembly: in Section 1D".

Repair Instructions

2
3
4
7
11
10
9. 3rd drive gear
10. 5th (Top) drive gear
11. 2nd drive gear
12. Gearshift fork shaft
13. Gearshift fork
14. Gearshift cam
15. Gearshift cam stopper plate
16. Gear position switch
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5
12
13
6) Remove the CKP sensor component parts and
disconnect the oil pressure switch lead wire. Refer to
"CKP Sensor Removal and Installation: in Section
1H" and "CKP Sensor Removal and Installation: in
Section 1H".
7) Remove the clutch component parts. Refer to
"Clutch Removal: in Section 5C".
8) Remove the gearshift shaft and gearshift driven
gear. Refer to "Gearshift Shaft / Gearshift Cam
Driven Gear Removal and Installation: ".
9) Remove the starter clutch component parts. Refer to
"Starter Clutch Removal and Installation: in Section
1I".
14
15
17
13
13
17. Gearshift cam stopper
: Apply oil.
: Apply molybdenum oil solution.
: Apply grease to oil seal lip.
: Apply thread lock to thread part.
: Apply thread lock to thread part.
: Do not reuse.
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16
I649G1520041-03