Fifth Gear Disassembly and Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

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.
Using special tool, remove circlip (1).
Special Tool

: 09900-06107
Remove 5th shift fork shaft bolt (2).
Remove gear shift fork (3) and 5th gear all together.

Fig 1: Removing Gear Shift Fork And 5th Gear
Courtesy of SUZUKI OF AMERICA CORP.
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
1. 09927-76060
  
  Fig 2: Installing Input Shaft 5th Gear And Special Tool To Stop Rotation Of Shafts
  Courtesy of SUZUKI OF AMERICA CORP.
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 Input Shaft 5th Gear
Courtesy of SUZUKI OF AMERICA CORP.