Manual Transmission Unit Disassembly

Remove clutch release bearing (1), release fork (2) and clutch housing (3).

Fig 1: Removing Clutch Release Bearing, Release Fork And Clutch Housing
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Remove back-up light switch (1).

Fig 2: Removing Back-Up Light Switch
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Remove locating screw (1), locating spring (2) and locating ball (3) as shown in the figure.

Fig 3: Removing Locating Screw, Spring And Ball
Courtesy of SUZUKI OF AMERICA CORP.
Remove return spring low bolt (1) and return spring reverse bolts (2).

Fig 4: Removing Return Spring Low Bolt And Return Spring Reverse Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Remove gear shift shaft inner bolt (1) / plug (2).

Fig 5: Removing Gear Shift Shaft Inner Bolt And Plug
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Using bolt hole, pull gear shift inner shaft (2) and then remove gear shift shaft inner lever (1).

Fig 6: Removing Gear Shift Shaft Inner Lever
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After removing transmission case bolts / nut, remove transmission rear case (1) from intermediate case (2).
Special tool

(A): 09912-34510

Fig 7: Removing Transmission Rear Case From Intermediate Case Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft bearing retainer (1) and gasket.

Fig 8: Removing Input Shaft Bearing Retainer And Gasket
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-rings (1) of input shaft bearing and C-ring (2) of counter shaft front bearing.
Special tool

(B): 09900-06107

Fig 9: Removing C-Rings Of Input Shaft Bearing And C-Ring Of Counter Shaft Front Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool (A), separate transmission front case (1) and transmission intermediate case (2).
Special tool

(A): 09912-34510

Fig 10: Separating Transmission Front Case And Transmission Intermediate Case Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Set transmission on workbench and remove transmission front case (1).
NOTE: To remove transmission front case, tilt it as shown.

Fig 11: Removing Transmission Front Case
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Set transmission intermediate case on vise securely.
Remove locating screws (1), locating springs (2) and locating ball (3) as shown in the figure.

Fig 12: Removing Locating Screws, Springs And Locating Ball
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool (C), remove spring pin and then remove 5th-reverse gear shift shaft (1).
Special tool

(C): 09922-85811

Fig 13: Removing 5th-Reverse Gear Shift Shaft Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove bolt from 5th gear shift fork (1).

Fig 14: Removing Bolt From 5th Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove 5th gear shift fork (1), 5th gear shift shaft (3) and reverse gear shift yoke (2).
NOTE: When pulling 5th gear shift shaft (3), place hand so as to catch balls (4) dropping from reverse gear shift yoke (2) and intermediate plate.

Fig 15: Removing 5th Gear Shift Fork, Shaft And Reverse Gear Shift Yoke
Courtesy of SUZUKI OF AMERICA CORP.
Remove locating roller No. 2 (1) from reverse gear shift shaft (2) by using magnet (3).

Fig 16: Removing Roller No. 2 From Reverse Gear Shift Shaft Using Magnet
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1) from reverse gear shift shaft (2) as shown in the figure.

Fig 17: Removing Circlip From Reverse Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove spring pin from reverse gear shift link component.
Special tool

(C): 09922-85811

Fig 18: Removing Spring Pin From Reverse Gear Shift Link Component
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse gear shift shaft (2), locating roller No. 1 (1), and reverse gear shift link component (3).
NOTE: When pulling gear shaft, hold locating roller No. 1 (1) with magnet (4) to prevent it from falling.
Disassemble reverse gear shift link component (3) by removing E-rings.

Fig 19: Holding Roller No. 1 With Magnet When Pulling Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove locating roller No. 2 (1) from low gear shift shaft (2) by using magnet (3).

Fig 20: Removing Roller No. 2 From Low Gear Shift Shaft Using Magnet
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1) from low gear shift shaft (2) as shown in the figure.

Fig 21: Removing Circlip From Low Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove bolt from low speed gear shift fork (1).

Fig 22: Removing Bolt From Low Speed Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Remove low gear shift shaft (2) and locating roller No. 1 (1).
NOTE: When pulling gear shaft (2), hold locating roller No. 1 (1) with magnet (3) to prevent it from falling.

Fig 23: Holding Roller No. 1 With Magnet When Pulling Gear Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1) from high gear shift shaft (2) as shown in the figure.

Fig 24: Removing Circlip From High Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove bolt from high speed gear shift fork (1).
Remove high gear shift shaft (2), high speed gear shift fork (1) and low speed gear shift fork (3).

Fig 25: Removing High Gear Shift Shaft, High Speed Gear Shift Fork And Low Speed Gear Shift Fork
Courtesy of SUZUKI OF AMERICA CORP.
Check countershaft 5th gear (1) thrust clearance by using thickness gauge (2).
Countershaft 5th gear thrust clearance

0.10 - 0.30 mm (0.0039 - 0.0118 in.)

Fig 26: Checking Countershaft 5th Gear Thrust Clearance Using Thickness Gauge
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (1) from counter shaft (2) as shown in the figure.

Fig 27: Removing Circlip From Counter Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove 5th speed synchronizer dog by using special tool (D).
Special tool

(D): 09941-84510

Fig 28: Removing 5th Speed Synchronizer Dog Using Special Tool
Courtesy of SUZUKI OF AMERICA CORP.
Remove synchronizer ring, needle bearing and counter shaft 5th gear.
Remove thrust washer (2) and ball (1).

Fig 29: Removing Thrust Washer And Ball
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse link stay (1) from intermediate case.

Fig 30: Removing Reverse Link Stay From Intermediate Case
Courtesy of SUZUKI OF AMERICA CORP.
Remove reverse idle gear (1) and shaft (2).

Fig 31: Removing Reverse Idle Gear And Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove main and counter shaft bearing plate (1).

Fig 32: Removing Main And Counter Shaft Bearing Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-ring (1) of countershaft rear bearing.
Special tool

(B): 09900-06107

Fig 33: Removing C-Ring Of Countershaft Rear Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Using rod (2) and hammer, remove counter shaft rear bearing (1) and counter shaft (3).
NOTE: This removal requires 2 persons. One should hold counter shaft (3) and the other should remove bearing (1) by using rod (2) and hammer.

Fig 34: Removing Counter Shaft Rear Bearing And Counter Shaft Using Rod And Hammer
Courtesy of SUZUKI OF AMERICA CORP.
Remove input shaft assembly (1) with synchronizer ring from main shaft assembly (2).
NOTE: When removing input shaft, be careful not to drop bearing roller.

Fig 35: Removing Input Shaft Assembly With Synchronizer Ring From Main Shaft Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Remove C-ring of main shaft and pull out main shaft assembly (1).

NOTE: If intermediate case is engaged with bearing firmly, tap front face of intermediate case with plastic hammer lightly as it will cause main shaft assembly to come off forward.

Fig 36: Pulling Out Main Shaft Assembly

Courtesy of SUZUKI OF AMERICA CORP.