Countershaft Gear And Driveshaft Gear Assembly - Suzuki 2005 GSF1200 Service Manual

Countershaft Gear and Driveshaft Gear
Assembly
Reassemble the countershaft and driveshaft gears in the
reverse order of disassembly. Pay attention to the
following points:
NOTE
When reassembling the transmission gears,
attention must be given to the locations and
positions of washers and snap rings. The
cross sectional view shows the correct
position of the gears, bushings, washers and
snap rings. Refer to "Transmission
Construction: ".
CAUTION
!
• Never reuse a snap rings. After a snap
rings has been removed from a shaft, it
should be discarded and a new snap rings
must be installed.
• When installing a new snap rings, do not
expand the end gap larger than required to
slip the snap rings over the shaft.
• After installing a snap rings, make sure
that it is completely seated in its groove
and securely fitted.
NOTE
• Before installing the gears, rotate the
bearing by hand to inspect for abnormal
noises and smooth rotation. Replace the
bearing if there is anything unusual.
• Before installing the gears, lightly coat the
driveshaft, countershaft and bushings with
molybdenum oil solution.
• Before installing the oil seal, apply SUZUKI
SUPER GREASE "A" to the oil seal lip.
: Moly paste 99000–25140 (SUZUKI Moly paste
or equivalent)
: Grease 99000–25010 (SUZUKI SUPER
GREASE A or equivalent)
• When installing a new snap ring (1), pay attention to
its direction. Fit it to the side where the thrust is as
B649G15206040
shown in the illustration.
"A": Thrust
Driveshaft Gear Assembly
• Align the bushing oil hole "A" with the shaft oil hole
"B".
• With the lock washer turned in its groove "C", align the
cutout "D" of the lock washer with the tab "E" on the
gear bushing.
• Install the spacer (1) after installing the O-ring (2).
Manual Transmission:
"A"
1
"B"
"B": Sharp edge
"B"
"A"
"C"
"D"
"E"
1 2
5B-15
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1. Snap ring
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