Suzuki VLR1800 Service Manual

Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions .................................................5-1
Precautions............................................................. 5-1
Precautions for Transmission / Transaxle............. 5-1
Manual Transmission.............................. 5B-1
Diagnostic Information and Procedures............5B-1
Manual Transmission Symptom Diagnosis ......... 5B-1
Repair Instructions ..............................................5B-2
Transmission Components ................................. 5B-2
Transmission Removal........................................ 5B-3
Transmission Installation ....................................5B-4
Transmission Construction.................................. 5B-7
Countershaft Gear / Driveshaft Gear
Disassembly and Assembly ..............................5B-8
Transmission Related Parts Inspection.............5B-11
Gear Position (GP) Switch Inspection............... 5B-12
Gear Position (GP) Switch Removal and
Installation.......................................................5B-12
Gearshift Lever Construction ............................ 5B-13
Gearshift Lever Removal and Installation .........5B-14
Gearshift Lever Height Inspection and
Adjustment ......................................................5B-14
Gearshift Shaft / Gearshift Cam Plate
Components....................................................5B-15
Gearshift Shaft / Gearshift Cam Plate
Removal and Installation................................. 5B-15
Gearshift Linkage Inspection ............................5B-18
Gearshift Shaft Oil Seal / Bearing Removal
and Installation................................................5B-19
Specifications.....................................................5B-20
Service Data......................................................5B-20
Tightening Torque Specifications......................5B-20
Special Tools and Equipment ...........................5B-21
Recommended Service Material .......................5B-21
Special Tool ......................................................5B-21
Clutch ....................................................... 5C-1
Precautions...........................................................5C-1
Precautions for Clutch System............................5C-1
Schematic and Routing Diagram........................5C-1
Clutch Cable Routing Diagram............................5C-1
Diagnostic Information and Procedures............5C-1
Clutch System Symptom Diagnosis ....................5C-1
Repair Instructions ..............................................5C-2
Clutch Lever Position Switch Inspection .............5C-2
Clutch Cable Removal and Installation ...............5C-2
Clutch Components.............................................5C-3
Clutch Removal...................................................5C-4
Clutch Installation................................................5C-6
Primary Driven Gear Removal and Installation ....5C-9
Clutch Parts Inspection .....................................5C-10
Specifications.....................................................5C-12
Service Data......................................................5C-12
Tightening Torque Specifications......................5C-12
Special Tools and Equipment ...........................5C-13
Recommended Service Material .......................5C-13
Special Tool ......................................................5C-13

Suzuki VLR1800 Specifications

General

Manufacturer	Suzuki
Model	VLR1800
Compression Ratio	10.5:1
Fuel System	Fuel injection
Starter	Electric
Transmission	5-speed
Category	Cruiser
Displacement	1783 cc
Ignition	Electronic ignition (Transistorized)
Final Drive	Shaft
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Rear Brakes	Single disc
Ground Clearance	140 mm
Seat Height	705 mm