Input Shaft and Counter Shaft

Removal





1. Remove 3 gear shift fork shaft bolts (6) with washers, then take out locating springs and steel balls.
2. Remove back up light switch (1).

NOTE: Removal of 5th to REV interlock bolt (5) is not necessary for removing gear shift and select shaft assembly.





3. Remove reverse shaft bolt (4) with washer.





4. Remove transmission case outside bolts (1) and clutch housing bolts.
5. Tapping left case flanges with plastic hammer, remove left case.
6. Pull out reverse gear shaft with washer, then take off reverse idler gear.
7. Pull out 5th and REV gear shift guide shaft together with 5th and REV gear shift shaft.

NOTE: When removing 5th and REV gear shift shaft and guide shaft, push up high speed gear shift shaft and shift it to 4th to facilitate removal of 5th and REV shifter.





8. Tapping input shaft end with plastic hammer, push it out as assembly from right case (1) a little, then take out input shaft assembly (5), countershaft assembly (4), high speed gear shift shaft (3) and low speed gear shift shaft (2) all at once.
9. Remove countershaft L bearing cup from left case.
10. Remove differential side L oil seal also from left case.

Installation





1. Join input shaft (5), countershaft (4), low speed gear shift shaft (2) and high speed gear shift shaft assemblies (3) all together, then install them into right case (1).

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





2. Install 5th and REV gear shift shaft (1) with 5th and REV gear shift guide shaft (2) into right case (5). Reverse gear shift arm (4) has to be joined with reverse gear shift lever (3) at the same time.





3. Make reverse idler gear (3) with reverse gear shift lever (4), insert reverse gear shaft (1) into case (2) through idler gear and then align A in shaft with B in case.

NOTE:
^ Make sure that washer (5) 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 (1) with sealant evenly then mate it with right case (2).
Sealant: SUZUKI BOND No.1215 99000-31110
5. Tighten case bolts (3) from outside to specified torque.
Tightening torque
Case bolt (b): 19 Nm (1.9 kgf-m, 14.0 ft. lbs.)





6. Install reverse shaft bolt (4) with aluminum washer and tighten it.
Tightening torque
Reverse shaft bolt (c): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
7. Install another 2 case bolts from clutch housing side and tighten them to specification.





8. Check locating spring for deterioration and replace with new one as necessary.





9. Install steel ball (3) and locating spring for respective gear shift shaft and tighten with bolt (1).
Tightening torque
Gear shift locating bolt (a): 13 Nm (1.3 kgf-m, 9.5 ft. lbs.)