Part 1
DISASSEMBLING UNITFifth Gears
1. Remove 8 bolts and take off transmission side cover.
2. Using special tool, remove circlip and then hub plate.
CAUTION: Care should be taken not to distort side cover when it is removed from left case.
Special Tool (A): 09900 - 06107
3. Remove shift fork plug and guide ball.
NOTE: Use of magnet would facilitate removal of guide ball.
4. Drive out spring pin by using special tool and hammer.
Special Tool (B): 09922 - 85811
5. Remove gear shift fork, sleeve & hub assembly, synchronizer ring spring, synchronizer ring and 5th gear all together. Gear puller is required for this work.
CAUTION: Be careful not to pinch synchronizer ring spring when removing.
6. Unfasten caulking of countershaft nut, install main shaft 5th gear and special tool to stop rotation of shafts, and then remove countershaft nut.
Special Tool (C): 09927 - 76010
7. Remove special tool, main shaft 5th gear, needle bearing and then counter shaft 5th gear. Gear puller would be necessary if spline fitting of counter shaft 5th gear is tight.
8. Remove 6 screws and take off left case plate, and then bearing set shim.
Gear Shifter, Main Shaft And Countershaft
1. Remove 3 bolts from left case cap and then take off cap.
2. Remove gear shift yoke bolt.
3. Remove 3 gear shift fork shaft bolts with washers, then take out locating springs and steel balls.
4. Remove 4 bolts from gear shift guide case, and then remove wiring harness clamp bracket and guide case.
5. Remove gear shift interlock bolt with washer.
6. Remove back up light switch.
NOTE: Removal of 5th to REV interlock bolt is not necessary for removing gear shift & select shaft assembly.
7. Pull out gear shift & select shaft assembly.
8. Remove reverse shaft bolt with washer.
9. Remove 11 case bolts from outside and another 2 from clutch housing side.
10. Tapping left case flanges with plastic hammer, remove left case.
11. Remove gear shift yoke.
12. Pull out reverse gear shaft with washer, then take off reverse idler gear.
13. Pull out 5th & REV gear shift guide shaft together with 5th & REV gear shift shaft.
NOTE: When removing 5th & REV gear shift shaft and guide shaft, push up high speed gear shift shaft and shift it to 4th to facilitate removal of 5th & REV shifter.
14. Tapping input shaft end with plastic hammer, push it out as assembly from case a little, then take out input shaft assembly, counter shaft assembly, high speed gear shift shaft and low speed gear shift shaft all at once.
15. Remove countershaft L bearing cup from left case.
16. Remove differential side L oil seal also from left case.
Right Case
1. Remove differential gear assembly from right case.
2. Remove bolt and then pull out speedometer driven gear.
CAUTION: Be careful not to damage speedometer driven gear case when removing it.
3. Remove input shaft oil seal by using special tools (combination of bearing remover and sliding shaft).
Special Tool
(A): 09930 - 30102
(B): 09923 - 74510
4. Also pull out countershaft R bearing cup by using bearing remover 09941-64511 with sliding shaft 09930-30102.
NOTE: If input shaft R bearing has been left in right case, pull it out by using bearing remover 09923-73210 with sliding shaft 09930-30102.
5. Remove bolt and then pull out gear shift arm.
6. Remove gear shift shaft bolt with washer, then take out spring and steel ball.
7. Remove gear shift shaft, boot and oil seal.
8. Remove differential side R oil seal from right case.
SUB ASSEMBLY SERVICE
RIGHT CASE
1. If reverse gear shift lever has been removed, fasten it with 2 bolts after applying thread lock cement.
Tightening Torque (a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
NOTE:
^ When installing reverse gear shift lever, set distance "a" between lever end and shaft bore to be 5 mm (0.2 inch).
Distance "a": 5 mm (0.2 inch)
^ Distance "a" can be measured by Installing reverse gear shaft provisionally.
^ When "a" is 5 mm (0.2 inch), clearance between reverse idler gear groove and shift lever end will be 1 mm (0.04 inch).
2. Install input shaft oil seal facing its spring side upward. Use special tool and hammer for installation and apply grease to oil seal lip.
"B": SUZUKI SUPER GREASE A, 99000 - 25010
Special Tool (A): 09951 - 76010
3. Install countershaft R bearing cup by using special tools and hammer.
Special Tool
(B): 09924 - 74510
(C): 09925 - 68210
4. Apply grease to gear shift shaft oil seal at its lip and install it up to bottom of the bore by using special tool and hammer.
"B": SUZUKI SUPER GREASE A, 99000 - 25010
Special Tool (D): 09925 - 58210
5. Install gear shift shaft, boot, steel ball, spring and tighten bolt with washer applied with sealant.
"C": SUZUKI BOND NO. 1215, 99000 - 31110
Tightening Torque (b): 13 Nm (1.3 kg-m, 9.5 ft. lbs.)
NOTE: Bring breather of gear shift shaft boot downward.
6. Install differential side R oil seal until it becomes flush with case surface by using special tool with hammer, and then apply grease to its lip.
NOTE: Face differential side oil seal spring side inward.
"B": SUZUKI SUPER GREASE A, 99000 - 25010
Special Tool (E): 09913 - 75810
7. Insert gear shift arm in gear shift shaft, then fasten them with bolt applied with thread lock cement.
Tightening Torque (c): 34 Nm (3.4 kg-m, 24.5 ft. lbs.)
LEFT CASE
1. If input oil gutter has been removed, install it with bolt applied with thread lock cement.
"A": Thread lock 1322, 99000 - 32110
Tightening Torque (a): 10 Nm (1.0 kg-m, 7.5 ft. lbs.)
2. Install differential side L oil seal until it becomes flush with case surface by using special tool with hammer, and then apply grease to its lip.
NOTE: Face oil seal spring side inward.
"B": SUZUKI SUPER GREASE A, 99000 - 25010
Special Tool (A): 09913 - 75520
3. Install countershaft L bearing cup into case bore by tapping it with plastic hammer lightly.
INPUT SHAFT ASSEMBLY
Disassembly
1. Remove input shaft R bearing by using bearing puller and press.
2. Drive out 5th gear spacer, L bearing and 4th gear all at once by using puller and press.
CAUTION:
^ To avoid gear tooth from being damaged, support it at flat side of bearing puller.
^ Stop press work in the middle way and take out 5th gear bush to prevent it from being compressed and then continue to remove bearing with gear.
3. Take out 4th gear needle bearing and high speed synchronizer ring.
4. Using special tool, remove circlip.
NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.
Special Tool (A): 09900 - 06107
5. Drive out high speed synchronizer sleeve & hub assembly together with 3rd gear by using puller and press.
CAUTION: Make sure to use flat side of puller to avoid causing damage to 3rd gear tooth.
6. Take out 3rd gear needle bearing from shaft.
7. Disassemble synchronizer sleeve & hub assembly.
Inspection And Reassembly
1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. If synchronizer parts need to be repaired, check clearance "a" between ring and gear, each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Clearance "a":
Standard 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit 0.5 mm (0.019 inch)
3. To ensure lubrication, air blow oil holes and make sure that they are free from any obstruction.
4. Fit high speed synchronizer sleeve to hub, insert 3 keys in it and then set springs as illustrated.
NOTE:
^ No specific direction is assigned to high speed synchronizer sleeve or each key but it is assigned as assembly.
^ Size of high speed synchronizer sleeve, hub, keys and springs is between those of low speed and 5th speed ones.
5. Drive in R bearing by using special tool and hammer.
Special Tool (A): 09925 - 98221
6. Install 3rd gear needle bearing, apply oil to it, then install 3rd gear and synchronizer ring.
7. Drive in high speed sleeve & hub assembly by using special tool and hammer.
NOTE:
^ While press-fitting sleeve & hub, make sure that synchronizer ring key slots are aligned with keys in sleeve & hub assembly.
^ Check free rotation of 3rd gear after press-fitting sleeve & hub assembly.
^ Needle bearings and synchronizer rings for 3rd and 4th are identical respectively.
Special Tool (B): 09913 - 84510
8. Install circlip, needle bearing, apply oil to bearing, then install synchronizer ring and 4th gear.
CAUTION: Confirm that circlip is installed in groove securely.
9. Press-fit L bearing by using special tool and hammer.
Special Tool (C): 09925 - 98221
10. Using the same special tool, drive in 5th gear spacer.
CAUTION: To prevent 5th gear spacer from being distorted because of excessive compression, do not press-fit it with L bearing at once.
COUNTERSHAFT ASSEMBLY
Disassembly
1. Drive out L bearing cone with 4th gear by using puller and press.
CAUTION:
^ Use puller and press that will bear at least 5 ton (11 ,000 lbs.) safely.
^ To avoid tooth damage, support 4th gear at flat side of puller.
2. Apply puller to 2nd gear and drive out 3rd & 4th gear spacer together with 2nd gear by using press. Needle bearing would come out with 2nd gear.
CAUTION: If compression exceeds 5 ton (11,000 lbs.), release compression once, reset puller support and then continue press work again.
3. Take out 2nd synchronizer ring.
4. Using special tool, remove circlip.
NOTE: Correct tool tips to be flat to facilitate removal of circlip.
Special Tool (A): 09900 - 06107
5. Apply puller to 1st gear and drive out low speed synchronizer sleeve & hub assembly with gear by using press.
6. Disassemble synchronizer sleeve & hub assembly.
7. Take out needle bearing from shaft.
8. Remove R bearing cone by using puller, metal stick and press.
Inspection And Reassembly
1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. If synchronizer parts need to be repaired, check clearance "a" between ring and gear, each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Clearance "a":
Standard 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit 0.5 mm (0.019 inch)
3. To ensure lubrication, air blow oil holes and make sure that they are free from any obstruction.
4. Fit high speed synchronizer sleeve to hub, insert 3 keys in it and then set springs as illustrated.
NOTE:
^ No specific direction is assigned to low speed synchronizer hub or each key but it is assigned as assembly.
^ Size of low speed synchronizer keys and springs are the largest compared with those of high speed and 5th speed ones.
5. Install R bearing cone by using special tool and hammer.
Special Tool (A): 09923 - 78210
6. Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring.
NOTE:
^ Key slot width of 1st synchronizer ring is smaller than that of 2nd synchronizer ring. Distinguish the difference properly.
Width
"b": 8.2 mm (0.32 inch)
"c": 9.6 mm (0.38 inch)
^ Needle bearings for 1st and 2nd gear are identical.
7. Drive in low speed sleeve & hub assembly by using special tool and hammer.
NOTE:
^ Support shaft with special tool as illustrated so that retainer of bearing cone will be free from compression.
^ Make sure that synchronizer ring key slots are aligned with keys while press-fitting sleeve & hub assembly.
^ Check free rotation of 1st gear after press-fitting sleeve & hub assembly.
Special Tool
(A): 09923 - 78210
(B): 09925 - 18010
(C): 09940 - 53111
8. Install circlip, needle bearing, apply oil to bearing, then install 2nd gear synchronizer ring and 2nd gear.
CAUTION: Confirm that circlip is installed in groove securely.
9. Press-fit 3rd gear and spacer by using special tool and 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
(A): 09923 - 78210
(D): 09913 - 80112
10. Press-fit 4th gear by using the same procedure as the above.
11. Install L bearing cone by using special tool and hammer.
NOTE: For protection of bearing cone, always support shaft with special tool as illustrated.
Special Tool
(A): 09923 - 78210
(E): 09925 - 98221
GEAR SHIFTER
Gear Shift & Select Shaft Assembly
1. To disassemble component parts, use special tools and 2.8 - 3.0 mm (0.11 inch) pin remover in addition.
Special Tool
(A): 09922 - 85811 (4.5 mm)
(B): 09925 - 78210 (6.0 mm)
2. Clean all parts thoroughly, inspect them and replace with new ones as required.
3. Assemble component parts by reversing removal procedure.
NOTE:
^ When driving in spring pins, prevent shaft from being bent by supporting it with wood block.
^ Assemble 5th & REV gear shift cam by winding cam guide return spring, and then drive in spring pin.
^ Locate low speed select spring (Blue-Lower position) and reverse select spring (Red-Upper position) correctly.
High Speed and Low Speed Gear Shift Shafts
Inspection
1. Using feeler gauge, check clearance between fork and sleeve and replace those parts if it exceeds limit of 1.0 mm (0.039 inch)
NOTE: For correct judgement of parts replacement, carefully inspect contact portion of fork and sleeve.
Clearance "a": Service limit 1.0 mm (0.039 inch)
2. Insert each gear shift shaft into case and check that it moves smoothly. If it doesn't, correct by using oilstone, reamer or the like.
5th & REV Gear Shifter
1. Disassemble component parts by using special tool and hammer.
Special Tool (A): 09922 - 85811 (4.5 mm)
2. Replace or correct parts as required and assemble shafts making sure that component parts are in proper order as shown.
NOTE:
^ Distinguish reverse gear shift arm spring (Blue) from low speed locating spring (Purple).
^ Install 2 steel balls in reverse gear shift arm without fail.
^ Drive in spring pin for reverse shift arm facing slit A toward front.