Gear Shift Lever Case Disassembly and Assembly: Assembly

Wash and inspect each part and replace if necessary. Also check item as described below and correct whatever necessary carefully using reamer, oilstone and the like, wash it thoroughly and reassemble it.
Item to be checked is;
- Shift shaft should go into case smoothly.
Insert shift shaft (1) as shown in the figure while making sure that inner parts are in proper direction.
NOTE:
- Cut off portion (3) in shift shaft (1) should face downward when shift shaft (1) is installed.
- Shift lever (2) should be installed at the same time.
  
  Fig 1: Identifying Shift Shaft, Shift Lever & Portion
  Courtesy of SUZUKI OF AMERICA CORP.
Drive in spring pins (2) for gear shift lever (5) and shift arm (7).
NOTE: When driving in spring pins, position their slits 180° ± 30° apart.

Special Tool

(A): 09925-78210
Apply sealant to new case plug (8) and drive it into lever case (1).
"B": Sealant 99000-31110
Apply grease to shift lever bush (9) and install it.
"A": Grease 99000-25010

Fig 2: Identifying Spring Pins, Gear Shift Lever, Shift Arm, Case Plug, Lever Case, Bush, Inner Spring Pin, Outer Spring Pin & Gear Shift Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install case plate (2) to gear shift lever case (1) and tighten them to specified torque.
Tightening torque

Gear shift lever case plate screw b: 6 N.m (0.6 kg-m, 4.5 lb-ft)

Fig 3: Identifying Gear Shift Lever Case & Plate
Courtesy of SUZUKI OF AMERICA CORP.
Install gear shift lever case (2) to transmission without using sealant for functional check.
Install shift control lever and check to make sure that it shifts smoothly according to shift pattern as shown in the figure.
NOTE:
- Apply thread lock cement "C" to control lever locating bolts (1) when retightening.
- Be sure to apply sealant to mating surface of gear shift lever case (2) for its final installation.
"C": Thread lock cement 99000-32110

Tightening torque

Transmission control lever locating bolt a: 17 N.m (1.7 kg-m, 12.5 lb-ft)

Fig 4: Identifying Transmission Control Lever Locating Bolts & Gear Shift Lever Case
Courtesy of SUZUKI OF AMERICA CORP.