Transmission Disassembly
- Remove clutch release bearing, release fork and clutch housing from input shaft. Remove backup light switch. See Fig 1
.
- Remove locating screw. See Fig 2
. Use a magnet to remove locating spring and locating ball. Remove return spring low bolts and return spring reverse bolts. Remove gearshift shaft inner bolt and plug. Using a punch, insert into gear shift shaft inner lever bolt hole, pry gear shift inner shaft outward. Remove gear shift shaft inner lever.
- Remove transmission case bolt and nuts. Use case separator to remove transmission rear case from intermediate case. Remove input shaft bearing retainer and gasket. Remove "C" rings from input shaft bearing and countershaft front bearing. See Fig 1
.
- Use case separator to separate transmission front case and transmission intermediate case. Remove locating screws, springs, and metal balls from intermediate case. See Fig 4
. Using spring pin remover and a hammer, remove spring pin from intermediate case. Remove 5th-Reverse gearshift shaft.
- Remove bolt from 5th gearshift fork. Remove 5th gearshift fork, 5th gearshift shaft and reverse gearshift yoke. Remove locating roller No. 2 from reverse gear shift shaft using a magnet.
- Remove circlip from reverse shift shaft component. Remove spring pin using a spring pin remover from reverse gearshift link.
- Remove locating roller No. 1 from reverse gear shift shaft using a magnet. Remove "E" ring to disassemble reverse gear shaft shift link. Use magnet to remove locating roller No. 2 from low gear shift shaft.
- Remove circlip from low gear shift shaft. Remove bolt from low speed gear shift fork. Remove low gear shift shaft. Use magnet to hold and remove locating roller No. 1.
- Remove circlip from high gear shift shaft. Remove bolt from high-speed shift fork. Remove high gear shift shaft, high-speed gear shift fork and low speed gear shift fork.
- Using thickness gauge, inspect countershaft 5th gear thrust clearance. Minimum clearance is .004-.012" (.10-.30 mm). Remove circlip from countershaft. Use an inner bearing puller to remove 5th speed synchronizer dog. Remove synchronizer ring, needle bearing and countershaft 5th gear.
- Remove thrust washer and ball. Remove reverse link stay from intermediate case. Remove reverse idler gear and shaft. Remove bolt and main and countershaft bearing plate from intermediate case. Remove "C" ring from countershaft rear bearing.
- Remove countershaft rear bearing and countershaft using a rod and hammer. Remove input shaft assembly and synchronizer ring from main shaft assembly. Remove "C" ring and main shaft assembly from intermediate case.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.