Suzuki LT-Z400, Service Manual

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Manual Transmission: 5B-1
Transmission / Transaxle
Manual Transmission
Diagnostic Information and Procedures
Manual Transmission Symptom Diagnosis
B933H25204001
Repair Instructions
Reverse Lock Cable Play Inspection and
Adjustment
B933H25206001
The cable adjuster is located at inside of the fuel tank
right side cover.
Inspect and adjust the reverse lock cable play “a” as
follows:
Reverse lock cable play “a”
1 – 2 mm (0.04 – 0.08 in)
1) Loosen the lock-nut (1).
2) Turn the adjuster (2) in or out until the reverse lock
cable play “a” should be 1 – 2 mm (0.04 – 0.08 in) at
the reverse lock release knob.
3) Tighten the lock-nut (1) securely.
4) After a adjustment, be sure to check for reverse lock
function.
Condition Possible cause Correction / Reference Item
Engine is noisy (Noise
seems to come from the
transmission) Worn or rubbing gears. Replace.
Worn countershaft splines. Replace countershaft.
Worn driveshaft splines. Replace driveshaft.
Worn or rubbing primary gears. Replace.
Worn bearings. Replace.
Transmission will not
shift Broken gearshift cam. Replace.
Distorted gearshift forks. Replace.
Worn gearshift pawl. Replace.
Transmission will not
shift back Clutch cable out of adjustment Adjust
Broken gearshift shaft return spring. Replace.
Rubbing or stuck gearshift shaft. Repair or replace.
Worn or distorted gearshift forks. Replace.
Transmission jumps out
of gear Clutch cable out of adjustment Adjust
Worn shifting gears on driveshaft or
countershaft. Replace.
Worn or distorted gearshift forks. Replace.
Weakened gearshift stopper spring. Replace.
Worn gearshift cam stopper plate. Replace.
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I933H1520001-01
1
2
I933H1520002-01
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