Suzuki Intruder 1978 Service Manual page 168

1. Upper Sprocket
2 . Lower Sprocket
3. Tensioner Spring
Fig ure 3-149
Jackshaft and Brake Disc
Removal
1. Remove belt guard and drive belt.
2. Remove left side trim from lower pan .
3 . Remove driven converter.
4. Remove the chaincase cover to drain the
chaincase.
5. Remove chain tensioner spring and upper
chain sprocket and spacer.
NOTE: It may be necessary to remove the lower
sprocket a Iso.
6. Loosen brake lever adjusting nut so disc
rotates free ly. Remove the three bolts and nuts
and bearing flange from bearing housing .
7. Turn jackshaft and disc so key is on top to
prevent it from fall ing out and remove jack
shaft from t he chaincase . Remove the brake
disc from between the calipers.
Cleaning and Inspection
1. Loosen the set screw and collar and remove
the bearing from the jackshaft . Replace the
bearing if damaged or it turns rough.
2. Clean the brake disc with so lvent and dry. Do
not allow oil or grease on disc as it impairs
braking act ion. Replace the disc assembly if the
disc is scored or warped .
Installation
1. Slide brake disc assembly between brake
calipers .
2. Insert key into jackshaft and slide jackshaft
through brake disc assembly into chaincase.
3. Sl ide lock collar and bearing onto jackshaft and
into bearing hous ing. Do not lock collar at this
time . Install bearing flange.
4 . Install upper sprocket spacer, sprockets, chain
and tensioner. Torque the upper sprocket
mounting bolt 40 to 50 ft Ib (5.53-6 .92 kg-m).
Torque the lower sprocket mounting bolt to 35
ft Ib (4.84 kg-m) .
5. Install chaincase cover and fill chaincase with
fluid until fluid is one half way up in the
window in the chaincase cover.
6. Pull the jacks haft toward the left side of the
snowmobile to seat the top sprocket spacer
against the bearing . With a hammer and punch
lock the bearing collar in the direction of shaft
rotat ion . Tighten set screw to prevent collar
from loosening.
7. Install driven converter and check alignment as
described in Section 2.
8. Install left side trim to lower pan.
Steering and Skis
Handlebars and Column Removal
(See Figure 3-150.)
1. Disconnect electrica l connectors from the main
harness so handlebars can be removed.
2. Disconnect the control cab les from the
handles.
3. Remove four mounting screws from the handle
holder . The handlebars can now be removed .
4. Removal of the steering co lumn requires the
prior removal of the intake silencer and en-
gine as previously described in this section.
STEER ING AND SKIS 3-95