Manual Transmission Upper Case, Shifter Disassembly & Assembly: Assembly

Interlock system is as shown in the following figure.

Fig 1: Identifying Interlock System Components

Courtesy of SUZUKI OF AMERICA CORP.

1. With fork installed to reverse gear shift shaft (1), install in into case and put in interlock ball (2).
   Fig 2: Installing Reverse Gear Shift Shaft & Interlock Ball

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE:

   • Reverse gear shift fork spring pin is different from other spring pins in length. It is longer than other spring pins.
     Fig 3: Identifying Gear Shift Forks & Gear Shift Fork Spring Pins

     Courtesy of SUZUKI OF AMERICA CORP.
   • When pressing gear shift fork spring pin (1) into reverse gear shift fork (2), do not allow to go all the way in, but leave its end protruded as much as the length shown in the figure.
     Fig 4: Identifying Installation Position Of Reverse Gear Shift Fork Spring Pin

     Courtesy of SUZUKI OF AMERICA CORP.
2. With interlock pin fit to high speed gear shift shaft (2), insert it into case and set fork with spring pin and then put in interlock ball (3).
   NOTE:

   • Note that high speed gear shift shaft (2) can't be inserted unless reverse gear shift shaft (1) is placed at neutral position.
   • When inserting high speed gear shift shaft (2), use care not to drop interlock pin.
     Fig 5: Identifying High Speed Gear Shift Shaft, Reverse Gear Shift Shaft & High Speed Gear Shift Shaft Interlock Ball

     Courtesy of SUZUKI OF AMERICA CORP.
3. With both reverse and high speed gear shift shafts placed at neutral position, insert low speed gear shift shaft (1) into case and fix fork with spring pin. Then apply sealant to rubber plug (2) and fit it in.

   "A":  Sealant 99000-31110

   Fig 6: Identifying Low Speed Gear Shift Shaft & Rubber Plug

   Courtesy of SUZUKI OF AMERICA CORP.
4. Confirm that interlock system operates properly by checking the followings.
   • When shifted to low position (or 2nd position), shifting of 3rd / 4th speed or 5th / Rev speed is not available.
     Fig 7: Identifying Low Speed, High Speed & Reverse Gear Shift Shafts

     Courtesy of SUZUKI OF AMERICA CORP.
   • When shifted to reverse position (or 5th position), shifting of 1st / 2nd speed or 3rd / 4th speed is not available.
   Fig 8: Identifying Reverse, Low Speed & High Speed Gear Shift Shafts

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install locating balls and locating springs and then set washers and bolts.

   Tightening torque 

   Locating spring bolt (a):  28 N.m (2.8 kg-m, 20.5 lb-ft)

   Fig 9: Identifying Locating Springs Bolts

   Courtesy of SUZUKI OF AMERICA CORP.