Before installing the gears, lightly coat MOLY PASTE or engine oil to the driveshaft and countershaft.
- 99000-25140: SUZUKI MOLY PASTE
Before installing the O-ring, apply SUZUKI SUPER GREASE to it.
- 99000-25030: SUZUKI SUPER GREASE "A" (USA)
- 99000-25010: SUZUKI SUPER GREASE "A" (Others)
Note: * Rotate the bushings by hand to inspect for smooth rotation. Replace the bushings if there is anything unusual.
Caution!
- Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.
- When installing a new snap ring, do not expand the end gap larger than required to slip the snap ring over the shaft.
- After installing a snap ring, make sure that it is completely seated in its groove and securely fitted.
Note: When reassembling the transmission, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, bushings, washers and snap rings. (3-77)
When installing a new snap ring, pay attention to the direction of the snap ring. Fit it to the side where the thrust is as shown in the illustration.
(A) Thrust; (B) Sharp edge
Caution! When installing the 6th drive gear, 3rd driven gear and 4th driven gear bushings onto the shaft, align the shaft oil hole (A) with the bushing oil hole (B).
(1) 6th drive gear bushing
(2) 3rd driven gear bushing
(3) 4th driven gear bushing
After installing the 3rd driven gear (4) onto the driveshaft, install lock washer No.2 (5) onto the driveshaft, and position it so it fits into the groove.
Then, fit lock washer No.1 (6) into lock washer No.2 (5).
1. 1st (Low) drive gear/countershaft; 2. 5th drive gear; 3. 3rd/4th drive gear; 4. 6th (Top) drive gear; 5. 2nd drive gear; 6 1st (Low) driven gear; 7. 5th driven gear; 8. 4th driven gear; 9. 3rd driven gear; 10. 6th (Top) driven gear; 11. 2nd driven gear; 12. 145 N·m (14.5 kgf·m, 105 lb·ft)
Gearshift fork to groove clearance
Using a thickness gauge, check the gearshift fork clearance in the groove of its gear.
The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action.
Shift fork to groove clearance:
- Service Limit: 0.50 mm (0.020 in)
- 09900-20803: Thickness gauge
- 09900-20102: Vernier calipers
If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.
Gearshift fork groove width
Measure the gearshift fork groove width using the vernier calipers.
Shift fork groove width:
- Standard: 5.5-5.6 mm (0.217-0.220 in)
- 09900-20102: Vernier calipers
Gearshift fork thickness
Measure the gearshift fork thickness using the vernier calipers.
Shift fork thickness:
- Standard: 5.3-5.4 mm (0.209-0.213 in)
- 09900-20102: Vernier calipers
