Gear Shifter, Input Shaft and Counter Shaft

INSTALLATION





1. Join input shaft, countershaft, low speed gear shift shaft and high speed gear shift shaft assemblies all together, then install them into right case.

NOTE:
^ Input shaft R bearing on shaft can be installed into right case by tapping shaft with plastic hammer.
^ Check to make sure that counter shaft is engaged with final gear while installing.





2. Install 5th & REV gear shift shaft with 5th & REV gear shift guide shaft into right case. Reverse gear shift arm has to be joined with reverse gear shift lever at the same time.





3. Make reverse idler gear with reverse gear shift lever, insert reverse gear shaft into case through idler gear and then align A in shaft with B in case.

NOTE:
^ Make sure that washer has been installed in shaft at above the gear.
^ Check to confirm that reverse gear shift lever end has clearance 1 mm (0.04 inch) to idler gear groove.





4. Clean mating surfaces of both right and left cases, coat mating surface of left case with sealant evenly then mate it with right case.
Sealant: SUZUKI BOND No. 1215, 99000-31110
5. Tighten case bolts from outside to specified torque.
Tightening Torque
(b): 19 Nm (1.9 kg-m, 14.0 ft. lbs.)
6. Install reverse shaft bolt with aluminum washer and tighten it.
Tightening Torque
(c): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)

7. Install another case bolts from clutch housing side and tighten them to specification.








8. Check locating springs for deterioration and replace with new ones as necessary.
9. Install steel ball and locating spring for respective gear shift shaft and tighten with bolt.
Tightening Torque
(a): 13 Nm (1.3 kg-m, 9.5 ft. lbs.)