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Fifth Gear Disassembly and Assembly: Disassembly

  1. Remove 9 bolts and take off transaxle side cover.
    CAUTION: Care should be taken not to distort side cover when it is removed from left case.
  2. Using special tool, remove circlip (1).

    Special tool 

    (A): 09900-06107

  3. Remove 5th shift fork shaft bolt (2).
  4. Remove gear shift fork (3) and 5th gear all together.
    Fig 1: Removing Circlip
    G00764248Courtesy of SUZUKI OF AMERICA CORP.
  5. Unfasten caulking of countershaft nut (2), install input shaft 5th gear (1) and special tool to stop rotation of shafts, and then remove countershaft nut (2).

    Special tool 

    (A): 09927-76060

    Fig 2: Removing Countershaft Nut
    G00764249Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (1). Gear puller (2) would be necessary if spline fitting of countershaft 5th gear is tight.
    Fig 3: Removing Countershaft 5th Gear
    G00764250Courtesy of SUZUKI OF AMERICA CORP.
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