Locknut Nut Clutch Honda Wave

Remove the cam gear slowly as the small pawls, pins and springs are loose and will fall out during removal.

11. Slowly remove the cam gear assembly (Figure 7) from the stopper plate. As soon as the pawls start to clear the stopper plate hold them in place with your fingers to avoid loosing the small parts. Place the assembly into the small cap from an aerosol spray container (Figure 8) then place into a recusable plastic bag to avoid misplacing any small parts.

12. Remove the stopper plate (Figure 9) and washer (Figure 10) from the end of the shift drum.

13. If necessary, remove the screw and bearing retainer (Figure 11).

14. While the cover is removed, remove the oil jet (Figure 12) from the crankcase.

Inspection

1. Clean all parts in solvent and dry with compressed air.

2. Inspect the return spring (A, Figure 13) on the gearshift shaft assembly. If broken or weak it must be replaced.

3. Inspect the gearshift shaft assembly (B, Figure 13) for bending, wear or other damage; replace if necessary.

4. Inspect the gear teeth (Figure 14) on the gearshift shaft assembly. If broken or damaged the gearshift shaft must be replaced.

5. Disassemble the cam gear assembly (Figure 15) and inspect the pawls, springs and pins for wear or damage. Replace any worn or damaged parts.

Suzuki Intruder Cam Install

6. Inspect the ramps (Figure 16) on the backside of the stopper plate for wear or damage. Replace the stopper plate if necessary.

7. Inspect the cam driven gear receptacle (Figure 17) in the stopper plate for wear or damage. Replace the stopper plate if necessary.

8. Inspect the gear teeth (Figure 18) on the cam drive gear. If broken or damaged the cam drive gear must be replaced.

9. Assemble the cam gear assembly as follows:

a. Install the springs into the cam gear body.

b. Position the pawl pins with the rounded end facing out and install them onto the springs.

c. Install the pawls onto the pins and into the cam gear body (Figure 19).

d. The pin grooves in the pawls are offset. When the pawls are installed correctly the wider shoulder must face toward the outside (Figure 20).

e. Hold the pawls in place and put the assembly into an aerosol can top (Figure 21).

10. inspect the gearshift cover (A, Figure 22) for wear or damage.

Suzuki Intruder 1400 Clutch SpringsSuzuki Marauder Ring Install

11. Check the gearshift shaft seal (B, Figure 22) for deterioration or signs of leakage. Replace if necessary.

12. Inspcct the O-ring seal (A, Figure 23) for hardness or deterioration, replace as necessary. Make sure the oil control orifice (B, Figure 23) is clear. Clean out with solvent and compressed air.

13. Inspect the oil jet O-Ring and replace if damaged.

Installation

CAUTION To prevent the following screws from working loose, apply a small amount of red ThreeBond TBI360 or Loctite No. 271 to the screw threads prior to installation.

1. Position the oil jet as shown in Figure 12 and install the jet in the crankcase receptacle.

2. If removed, install the bearing retainer and scrcw (Figure 11). Tighten the screw securely.

3. Install the washer (Figure 10) onto the end of the shift drum.

4. The locating pins on the end of the shift drum are offset. Correctly align the locating pin receptacles in the backside of the stopper plate (Figure 24) with the shift drum pins and install the stopper plate (Figure 9). Push it in until it stops.

5. Remove the cam gear assembly from the cap. Compress the spring-loaded shift storage pawls with your fingers (Figure 25). Install the cam gear assembly into the receptacle of the cam driven gear (Figure 7).

6. Align the cam retainer locating tab (Figure 26) with the notch in the shift drum and temporarily install the cam retainer and Allen bolt and tighten finger-tight at this time.

7. Install the pawl lifter, nut and screw and tighten the screw and nut securely.

8. Install the bearing retainer (Figure 27) in placc on the lower bolt hole.

9. Install the lower screw and collar on the upper screw (Figure 28) and install the cam guide (Figure 29) onto the crankcase. Tighten the screws securely.

10. Assemble the cam stopper assembly in the order shown in Figure 30. Do not forget the small inner screw (Figure 31).

11. Install the cam stopper assembly (Figure 32) into the crankcase and tighten securely.

12. Use narrow nose Locking pliers to pull the spring up and over the top of the cam stopper arm. Hook the spring end onto the locator (A, Figure 33) on the cam stopper and make sure the other end of the spring is against the crankcase wall (B, Figure 33). The spring must be in this position for the cam stopper arm to operate correctly.

13. Remove the Allen bolt and cam retainer.

14. Remove the cam stopper assembly (Figure 32).

15. Make sure the washer (Figure 34) is in place on the gearshift shaft.

Suzuki Intruder Cam InstallIntruder 1400 Electrical Assembly

16. Apply clean engine oil to the gearshift shaft and install the gearshift shaft (Figure 35) part way into the crankcase. Align the center of the cam driven gear with the center of the gearshift shaft gear (Figure 36), then push the shaft assembly all the way in making sure the return spring is meshed correctly with the locator pin (Figure 37).

NOTE

The alignment of the 2 gears (Figure 38) is essential for proper gearshift operation. If alignment is incorrect, the

Suzuki Intruder Cam InstallHonda Wave 125r One Way ClutchSuzuki Intruder Cam Install

shift mechanism will operate poorly or not at all.

17. Recheck the alignment of the center of the cam driven gear to the center of the gearshift shaft gear (Figure 39). This alignment is necessary for proper gear shift operation. If necessary, realign the two gears at this time.

18. Align the cam retainer locating tab (Figure 40) with the notch in the shift drum and temporarily install the cam retainer and Allen bolt (Figure 41) and tighten securely.

19. Recheck the alignment of the ccntcr of the cam driven gear to the center of the gearshift shaft gear (Figure 42). This alignment is necessary for proper gear shift operation. If necessary, realign the 2 gears at this time.

20. If removed, install the locating dowels (A. Figure 43) and a new gasket (B, Figure 43).

NOTE

A gasket washer is located under the lower three bolts. These gasket washers must be reinstalled on the same three bolts to prevent an oil leak.

Drz400sm Clutch Wavy Washer LocationSuzuki Intruder 1400 Clutch Springs

21. Install the external gearshift mcchanism cover and bolts. Be sure to install a gasket washer under the lower three bolts (Figure 44). Tighten the bolts securely

22. Install the neutral switch, plunger and spring as described in Chapter Nine.

23. Install the clutch slave cylinder as described in this chapter.

24. Install the front footpeg assembly as described in Chapter Thirteen.

25. Install the exhaust system as described in Chapter Eight.

CLUTCH Removal/Disassembly

Refer to Figure 45 for this procedure.

1. Drain the engine oil as described in Chapter Three.

2. Shift the transmission into gear.

3. Remove the front footpeg assembly as described in Chapter Thirteen.

Drz400sm Clutch Wavy Washer LocationVs1400 Intruder Engine Head Covers

NOTE

Note the location of the wiring harness clamps and the sealing washers under two of the holts securing the clutch cover. During assembly these sealing washers must be reinstalled in their original position to prevent an oil leak.

4. Remove the bolts securing the clutch cover (Figure 46). Remove the clutch cover and gasket. Don't lose the locating dowels.

5. Place a shop rag between the primary drive gear and the clutch outer housing to keep the clutch assembly from rotating.

6. Using a crisscross pattern loosen the clutch bolts securing the pressure plate. Remove the shop rag.

NOTE

The pressure plate is held in place by 2 different spring sets. Each spring set consists of 4 bolts; spacers and springs. The spring set threaded into the clutch hub is longer than the spring set threaded into the clutch spring slider. Do not intermix the 2 spring sets when removing them in Step 7.

I. Remove the bolts, spacers and springs loosened in Step 6.

8. Remove the pressure plate.

9. Remove the friction discs, clutch plates, wave washer and wave washer scat.

10. Remove the thrust washer, bearing and clutch push piecc.

II. If necessary, remove the clutch left-hand pushrod from the transmission shaft.

CAUTION Do not overtighten the clutch holding tool in Step 12 or it may damage the clutch hub grooves.

12. Secure the clutch hub with a clutch holding tool (A, Figure 47).

13. Loosen, then remove the clutch locknut (B, Figure 47) and wave washer.

14. Remove the clutch tool from the clutch hub.

15. Slide off and remove the clutch cam No. 1 (A, Figure 48).

16. Slide off and remove the clutch cam No. 2 (B, Figure 48).

17. Remove the thrust washer (A, Figure 49) and the clutch spring slider (B, Figure 49).

Suzuki Intruder 1400 Clutch Springs
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