External Mechanism For Gear Shift; Final Assembly - Suzuki GS850G Service Manual

ENGINE
List of shims
CA IJTIOIV:
A , f m IIZP frnorlt
cor~tucr
adiristrnent is
rnodu, IJIP hacklush mlrsi be sech~cked,
a s
it ,nay r h a r z ~ ~ . Rcft~r to
the
hacklash
c - I I P c ~ ~ / I ~
s ~ ~ I ~ s ( ~ c t i o ? z ,
( I I ~
readjust
until
hot11 i~acklns11 rrrrd ~ n o t h contacf arc
cnrrecl.
-
I
I
I
FINAL ASSEMBLY
After
hot11 gear backlash and tooth contact
arc correct. remwe the
seconday
drive
gcar housing and secondavj
driven
zear
llousing from the crankcase.
Clean
off nnv machinist's
dye
or past from
the
gear
teetl~. and lubricate the teeth with
Hypoid gear oil.
Install
new
O-rings on the secondary drive
Part
No.
249
249
24935.45103
24935-45 104
and driven
gear
housings. Lightly grease
tlie
O-rings.
Install Ihc secondary drive and driven gear
Ilou5ings in
to
the crankcase.
Shim
thickness
0.35 m m
0.40 mrn
0.45
rnm
0.50 mm
NOTE:
Sr~ct>rrriny d r i v ~ and
driven
gear
h o ~ r s i t ~ ~ . ~ nwrsi
he irrsralied with the
f(~rters
"UP"
focirtg n~pward,
as
shown
in
F i ~ s .
7-169, 7-1 70.
a
*
Use
SUZWKI
THREAD LOCK "
1342" on
the threads of the housing bolts, and
tor-
que to specifics
tion.
Reinstall secondary gear drain plug and
I
torque to specification.
-
Thrc "'1 342"
Fill the gear cavitv
to
specified capacity.
340-400
m l (11.5-13.5 US
071
with
Hypoid gear oil.
Reinstall swing arm with propeller shalt
and rear wheel see section
(1 1-39 and 1 1-43)
Keimtall secondary drive gear outer cover.
99000-32050
Bolt
I
lgnrenlng
Torque
Drain
Plug
Torque
EXTERNAL MECHANISM
FOR GEAR SHIFT
REMOVAL
Remove gear shift lever.
Remove clutch cover and primary driven
gear (see page 7-35).
*
Extract gear shift
shaft from
crankcase.
2.0-2.6 kg-m
( 1 4.5-1 9.0 lb-ft)
2.0-3.0 kg-rn
(14.5-21.5 lb-ft)
INSTALLATION
InstafIation is carried out in the reverse
order of removal.
Install the gearshift shafts, with
the center
of the gear on shaft side
aligned the
center
of gearshift cam driven gear.
Fig. 7
Install clutch driven gear
and
clutch cover.
Replace gasket with a new one to prevent
oil leakage.