Manual Transmission Unit Disassembly

Remove 12 fastening bolts and separate rear case (3).
Remove clutch release bearing (2).
Remove 8 clutch housing bolts and then remove clutch housing (1).

Fig 1: Identifying Transmission Bolts & Clutch Release Bearing, (To Be Removed For Transmission Disassembly)
Courtesy of SUZUKI OF AMERICA CORP.
Remove 8 bolts and pull out input shaft bearing retainer (1) by using large size screwdrivers (2) and clean cloth (3).
CAUTION: When pulling out, do not scratch the transmission case surface contacting with the clutch housing.

Fig 2: Removing 8 Bolts & Pulling Out Input Shaft Bearing Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Remove 10 bolts and separate cases (1, 2) by using special tool.
Special tool

(A): 09912-34510

Fig 3: Removing 10 Bolts & Separating Cases
Courtesy of SUZUKI OF AMERICA CORP.
If equipped with scissors gears (3, 5), put match mark (1) (paint) on teeth of low (4) and reverse (6) gear assembly as shown in the figure before taking out and main shaft assembly from lower case (2).

Fig 4: Putting Match Marks (Paint) On Teeth Of Low & Reverse Gear Assemblies
Courtesy of SUZUKI OF AMERICA CORP.
Take out input and main shaft assembly.
Remove bearing circlip (2) at the rear part of counter shaft by using screwdriver (1).

Fig 5: Removing Bearing Circlip From Rear Of Counter Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove bolt (3) for reverse idle gear shaft (2) and then remove idle gear (1) and shaft (2) as a set.

Fig 6: Identifying Reverse Idle Gear Shaft & Idle Gear Shaft Bolt
Courtesy of SUZUKI OF AMERICA CORP.
Remove center bearing plate (1) by removing its 2 bolts (2).

Fig 7: Identifying Center Bearing Plate & Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove outside circlip (1) of front bearing (2) on countershaft.

Fig 8: Identifying Countershaft & Front Bearing Outside Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Using plastic hammer, drive counter shaft (1) rearward.

Fig 9: Driving Counter Shaft Rearward
Courtesy of SUZUKI OF AMERICA CORP.
Pull out 5th gear (2) and rear bearing (1) with puller (3) and press.
NOTE:
- Apply pressing force while adjusting position of front bearing so that it will fit in its original position (hole in lower case).
- Be sure to set flat face of puller (3) against 5th gear so as not to cause damage to teeth.
  
  Fig 10: Identifying Rear Bearing, 5th Gear & Puller
  Courtesy of SUZUKI OF AMERICA CORP.
In the same manner as Step 12), drive countershaft reward again.
Pull out reverse gear (1) with puller (2) and press.

Fig 11: Identifying Reverse Gear & Puller
Courtesy of SUZUKI OF AMERICA CORP.
Pull out roller bearing by hand and then remove shaft from lower case.
Remove circlip (3) of counter shaft (1) front bearing (2) and pull out bearing (2) by using puller.
Special tool

(B): 09913-60910

Fig 12: Removing Counter Shaft Circlip & Front Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (2), friction gear retainer (3), friction gear spring (4), friction gear (5) and pin (6) from counter shaft (1) in that order.

Fig 13: Identifying Counter Shaft Circlip, Friction Gear Retainer, Friction Gear Spring, Friction Gear & Pin
Courtesy of SUZUKI OF AMERICA CORP.