Suzuki VX800 1990-1993 Service Manual 04 Shaft drive
CONTENTS
SHAFT DRIVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 1
SECONDARY BEVEL GEARS CONSTRUCTION - - - - - 8 - - - - - - - - . - - - 4- 2
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4_ 3
4- 3
4- 4
SECONDARY GEARS SHIM ADJUSTMENT..................4- 4
RdPKI dCU
Yrm”,\Lm”I I
TOOTH CONTACT
FINAL ASSEMBLY AND REMOUNTING
REASSEMBLY INFORMATION
FINAL BEVEL GEARS CONSTRUCTION
FINAL GEAR CASE BREATHER CIRCUIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..A A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-r- -r
4- 6
. . . . . . . ...*. . . . . . ..*. . ..4_ 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4_ 6
. . .., . . . . . . . . . . . . . . . . . . . . ..4_ g
AIR AND GEAR OIL FLOW IN FINAL GEAR
CASE BREATHER CIRCUIT
REMOVAL AND DISASSEMBLY
. . . . . ..*............................... 4_ g
.,..........................,....
4-10
lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FINAL GEAR SHIM ADJUSTMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13
4-16
FINAL GEAR BEARING CASE SHIM
CLEARANCE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
BACKLASH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16
TOOTH CONTACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
FINAL ASSEMBL Y A ND REMOUNTING - - - - - . - - - - - - . - - - - - - - - - . 4-19
REASSEM_BL Y iNFORM_A TiON
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4+7
1 -1
4-1 SHAFT DRIVE
SHAFT DRIVE
-
_
SECONDARY BEVEL GEARS CONSTRUCTION
SHAFT DRIVE 4-2
($ Bush
@ Secondary reduction gear
@ Circlip
8 ;;y ;og
rln
@ Bolts
8 giy (5 kinds)
rln
8 ;iynsg (5 kinds)
rln
@ Oil seal housing
@ Oil seal
@ Bearing retainer
@ Bolts
@ Secondary bevel gear set
Tiahtenina toraue
w ”
Item
@
_
(iD
1 8
1 90 - 120 1 9.0 - 12.0 165.0 -87.0
.
N.m kg-m
18-28 1 .8
18-28 1 .8
lb-ft
- 2.8 13.0 - 20.0
- 2.8 13.0 - 20.0
1
4-3
SHAFT
DRIVE
rnF..l\\,A I
l3CMUVAL HIYIJ Ul3A33tMDLY
A .I_ -ICI A mer..mm .I
SECONDARY DRIVE BEVEL GEAR
l
Remove the engine. (See page 3-3.)
l
Remove the secondary drive bevel gear assembly. (See page
3-16.)
l
Compress the damper spring with a vice, and remove the
circlip with the special tool.
09900-06107 : Snap ring pliers
l
Remove the cam dog @ and damper spring 0.
SECONDARY DRIVEN BEVEL GEAR
l
Remove the secondary driven bevel gear assembly. (See page
3-l 5.)
l
Remove the bearing retainer with the special tool.
l
Remove the oil seal 0, oil seal housing @ and O-ring 0.
CAUTION:
The removed oil seal and O-ring should be replaced with new
ones.
INSPECTION
Inspect the removed parts for the following abnormalities.
* The drive and driven bevel gears must be inspected thoroughly for excessive wear
or damage. It is important that both gears be in good condition to maintain proper
tooth contact.
* Abnormal noise of bearings
* Bearing damage or wear.
SHAFT DRIVE 4-4
REASSEMBLY
Reassemble the secondary bevel gears in the reverse order of disassembly and also carry out the following
steps:
NOTE:
Before reassembly, thoroughly clean all parts in cleaning solvent.
_
l
Apply grease to the
(For U.S.A. model)
nnnnn
YYUUU-LcJU3U .
_
(For the other models)
‘)cn3tl .
CI ,7I IV,
J”L”lNl3”rL” ““Lr\3L
99000-25010 : SUZUKI SUPER GREASE “A”
CAUTION:
Always use a new oil seal and O-ring.
lip of oil seal and O-ring.
Cl
IL)CD
PDCACC “A”
0 Tighten the bearing retainer to the specified torque.
Tightening torque : 90 - 120 N-m
(9.0 - 12.0 kg-m, 65.0 - 87.0 lb-ft)
09921-21820
:
Bearing retainer wrench
SECONDARY GEARS SHIM ADJUSTMENT
BACi(ip-eii
l
Install the secondary drive bevel gear assembly and removed
shims, and tighten the three bolts @ to the specified torque.
Tightening torque : 18 - 28 N-m
(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)
4-5 SHAFT DRIVE
l
Install the secondary driven bevel gear assembly and rernn~~ri
II,“““” .2,11111.#, “ll.. C’LJ’“““’
chime 2nd tinhtnn the twn hnltc 0 tn thn cnerifid
CII” &I”.. ““IL1 ‘=/ L” LI.” .y”Y”,“U
torque.
NOTE:
Do not install the O-ring on the driven gear housing at this
point. O-ring is installed after backlash and tooth contact are
correct.
l
Hold the bearing with the special tool or secondary bevel
gear case.
09921-21810 : Bearing holder
Tightening torque : 18 - 28 N-m
(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)
l
instaii the backiash measuring
tooi on the drive bevei gear
cam dog, and set-up a dial gauge as shown in the illustration.
09924-34510 : Backlash measuring tool (27 - 50 mm)
I I
~___~__I_~._. ~~__.. ,___,.,__L
3econaary gear q acwasn
I
0.05 - 0.32
(0.002 - 0.013 in)
mm
Adjust the dial gauge so that it touches the backlash measuring tool arm at the mark; hold the driven bevel gear securely,
and turn the drive bevel gear in each direction, reading the
total backlash on the dial gauge.
If the backlash is not within specification, the shims must
be changed and the backlash should be re-checked until
correct.
Refer to the right chart for appropriate changes.
NOTE:
When changing the shims, measure the thickness of old shims.
Using the thickness of the old shims as a guide, adjust the
backlash by referring to the right chart.
I
I
Backlash
Under 0.05 mm
(0.002 in)
0.05 - 0.32 mm
(0.002 - 0.013 in)
Over 0.32 mm
(0.013 in)
List of shims @ (Refer to page 4-7)
Part No. Shim thickness
24945 - 05AOO
1 24945 - 05AOO - OBO 1 0.35 mm
24945 - 05AOO - OCO
e*fi*- ^_1^^ ^_,.
L4Y45 - USHUU - uuu
24945 - 05AOO - OEO 0.60 mm
-
OAO
Shim adjustment
Decrease shim
increase shim
thickness
Correct
thickness
0.30 mm
0.40 mm
^ r^
u.3u
mm
I
SHAFT DRIVE 4-6
TOOTH CONTACT
After hr;nn;nn thn hs&lrach within cnar;firat;nn h\/ rhzmninn
_1L.z8 “IIII
the
secondary driven bevel gear shims, it will be necessary to
y,,,y l.IIb UU~I.I”.JII ““lL,,1,, ~~~L,,,l”“Ll”,, uy ““““y”‘y
check tooth contact.
Remove the drive bevel gear assembly from the crankcase.
Clean and degrease the secondary drive bevel gear teeth, and
apply a coating of machinist’s layout dye or paste to several
teeth.
Reinstall the secondary drive bevel gear assembly, with
correct shim, onto the secondary gear housing.
Rotate the secondary driven bevel gear several turns in both
directions.
Remove the secondary drive bevel gear from the crankcase,
and observe the tooth contact pattern made in the dye or
paste.
If tooth contact is found to be correct, go to the
Final As-
sembly (See page 3-45).
If tooth contact is found to be incorrect, the shims of the
secondarv drive hwel near a.nr_l spc.n.n&rv ririwn hpvol ~PZW
L___..--_,
-.--_ -__-. J__.
, -..-_.. W.,_“. 3”‘.
must be changed, tooth contact should be re-checked until
correct.
$23 INCORRECT
(‘&
CORRECT
(Contact
at
tooth top)
CAUTION
:
After the tooth contact adjustment has been performed, the
backlash must be re-checked, because it may have changed.
Refer to the backlash check sub-section, and readjust until
tooth contact and backlash are both within the specifications. If you can not maintain the correct tooth contact when
adjusting backlash, both the drive and driven bevel gears
should be replaced.
Tooth contact
Contact
at tooth
top 0
Contact at tooth
root 0
List of shim @
Part No.
24945 - 05AOO - OAO
q--r- fiFAT\P. nlTn
I
L4Y45 - USHUU ulsu
Shim adjustment
Decrease thickness
of shims @ or (@
Increase thickness
of shims @ or @
Shim thickness
(
j
0.30 mm
n CIr __ ~_
u.x mm
List of shims @j
24935 38AOO - 030
L
Part No.
9oJxnn n3c
Shim thickness
0.30
mm
nTz,r;-,
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