Countershaft Disassembly and Reassembly: Reassembly

Reference: COUNTERSHAFT INSPECTION

Reference: GEAR SHIFT SHAFT AND FORK INSPECTION

Fit low speed synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
NOTE: No specific direction is assigned to low speed synchronizer hub and each key but it is assigned as assembly.

Fig 1: Synchronizer Key Installation Position
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse gear (1) to countershaft (2) using puller (3) and hydraulic press.

Fig 2: Driving In Reverse Gear To Countershaft Using Puller And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.
Install 1st gear spacer (1) using special tool and hydraulic press.
Special Tool
1. 09940-54910
  
  Fig 3: Driving In 1st Gear Spacer Using Special Tool And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.
Install 1st gear needle bearing (4), apply oil to it, then install 1st gear and 1st gear synchronizer ring (2).
Install low speed sleeve & hub assembly (1) using special tool and hydraulic press.
NOTE:
- Support lower speed synchronizer hub with special tool as shown in figure so that retainer of bearing cone will be free from compression.
- Make sure that synchronizer ring key slots are aligned with keys (5) while press-fitting sleeve & hub assembly.
- Check free rotation of 1st gear (3) after press-fitting sleeve & hub assembly.
Special Tool
1. 09944-77030
  
  Fig 4: Driving In Low Speed Sleeve & Hub Assembly Using Special Tool And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.
Install 2nd gear spacer (1) using special tool and hydraulic press.
Special Tool
1. 09945-55410
  
  Fig 5: Driving In 2nd Gear Spacer Using Special Tool And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.
Install 3rd gear (3), 2nd gear and 2nd gear synchronizer ring (1) using special tool and hydraulic press.
NOTE: It is recommended to press-fit spacer and 3rd gear first, and then 4th gear later separately so that countershaft will not be compressed excessively.

Special Tool
1. 09944-77030
  
  Fig 6: Driving In 3rd Gear, 2nd Gear And 2nd Gear Synchronizer Ring Using Special Tool And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.

Select new circlip (1) that will make thrust clearance "a" of bearing 0.15 mm (0.0059 in) or less and install it.

Fig 7: Identifying Circlip

Courtesy of SUZUKI OF AMERICA CORP.

Available circlip thickness

CIRCLIP THICKNESS SPECIFICATIONS

Clearance "b"	Select circlip
2.000 - 2.100 mm (0.0788 - 0.0826 in.)	2.00 mm (0.0788 in.)
2.100 - 2.200 mm (0.0826 - 0.0866 in.)	2.10 mm (0.0826 in.)
2.200 - 2.300 mm (0.0866 - 0.0905 in.)	2.20 mm (0.0866 in.)
2.300 - 2.400 mm (0.0905 - 0.0944 in.)	2.30 mm (0.0905 in.)
2.400 - 2.500 mm (0.0944 - 0.0984 in.)	2.40 mm (0.0944 in.)
2.500 - 2.600 mm (0.0984 - 0.1023 in.)	2.50 mm (0.0984 in.)

Install 4th gear (1) using puller and hydraulic press.

Fig 8: Driving In 4th Gear Using Puller And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.
Install 5th gear using the same procedure at step 7).
Install 6th gear (1) and 5th gear spacer (2) using special tool and hydraulic press.
Special Tool
1. 09945-55410
  
  Fig 9: Driving In 6th Gear And 5th Gear Spacer Using Special Tool And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.
Install countershaft left bearing (1) and washer using special tool and hydraulic press.
Special Tool
1. 09913-84510
  
  Fig 10: Installing Countershaft Left Bearing And Washer Using Special Tool And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.
Install countershaft right bearing (1) using special tool and hydraulic press.
Special Tool
1. 09913-84510
  
  Fig 11: Installing Countershaft Right Bearing Using Special Tool And Hydraulic Press
  Courtesy of SUZUKI OF AMERICA CORP.

Select new circlip (1) that will make thrust clearance "a" of bearing 0.1 mm (0.0039 in) or less and install it.

Fig 12: Identifying Circlip

Courtesy of SUZUKI OF AMERICA CORP.

Available circlip thickness

CIRCLIP THICKNESS SPECIFICATIONS

Clearance "b"	Select circlip
1.810 - 1.860 mm (0.0713 - 0.0732 in.)	1.81 mm (0.0713 in.)
1.860 - 1.910 mm (0.0732 - 0.0751 in.)	1.86 mm (0.0732 in.)
1.910 - 1.960 mm (0.0751 - 0.0771 in.)	1.91 mm (0.0751 in.)
1.960 - 2.010 mm (0.0771 - 0.0791 in.)	1.96 mm (0.0771 in.)
2.010 - 2.060 mm (0.0791 - 0.0811 in.)	2.01 mm (0.0791 in.)
2.060 - 2.100 mm (0.0811 - 0.0826 in.)	2.06 mm (0.0811 in.)
2.100 - 2.130 mm (0.0826 - 0.0838 in.)	2.10 mm (0.0826 in.)
2.130 - 2.160 mm (0.0838 - 0.0850 in.)	2.13 mm (0.0838 in.)
2.160 - 2.190 mm (0.0850 - 0.0862 in.)	2.16 mm (0.0850 in.)
2.190 - 2.220 mm (0.0862 - 0.0874 in.)	2.19 mm (0.0862 in.)
2.220 - 2.250 mm (0.0874 - 0.0885 in.)	2.22 mm (0.0874 in.)
2.250 - 2.280 mm (0.0885 - 0.0897 in.)	2.25 mm (0.0885 in.)
2.280 - 2.310 mm (0.0897 - 0.0909 in.)	2.28 mm (0.0897 in.)