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Transmission Disassembly

  1. Remove clutch release bearing and spring. Remove clutch release shaft. Using Bushing Remover (09925-48210), remove clutch release bushings from housing. Using 3 bolts (6 mm), remove input shaft retainer. Remove shifter housing bolts. Remove reverse shift rim bolt. Remove shifter housing.
  2. Remove case half bolts and separate case halves. Remove mainshaft assembly. Remove reverse gear shaft and gear. Using Puller (09913-65135), remove countershaft rear bearing. Remove countershaft 5th gear and reverse gear. Remove snap ring from countershaft. Remove countershaft with a hydraulic press. See Fig 1.
    Fig 1: Removing Countershaft
    G93G24121Courtesy of SUZUKI OF AMERICA CORP.
  3. Using puller, remove bearing. Carefully remove input shaft from mainshaft. DO NOT  allow high-speed hub assembly synchronizer to fall. Remove high-speed synchronizer sleeve retaining snap ring. Remove sleeve hub, 3rd driven gear and needle bearing from mainshaft. Remove rear bearing retaining snap ring from mainshaft. See Figure.
  4. Using puller, remove rear bearing. Remove 5th gear washer, ball and 5th gear. Remove 5th gear synchronizer ring and needle bearing. Remove reverse synchronizer hub retaining snap ring. Remove reverse synchronizer hub, reverse gear and needle bearing. Using a hydraulic press, remove bearing washer and reverse gear bushing. Remove ball and press center bearing from mainshaft.
    NOTE: Be careful not to lose ball during disassembly. DO NOT  remove ball bearing with bearing washer and reverse gear bushing.
  5. Remove 1st gear, needle bearing and washer (DO NOT  lose ball during disassembly), synchronizer ring and spring from mainshaft. Using a hydraulic press, remove 1st gear bushing, synchronizer hub, ring, spring, 2nd gear and 2nd gear bearing.
  6. Ensure all shift fork shafts are in neutral position. Using Spring Remover (09922-85811), remove yoke pin from each shift fork. DO NOT  drive pin so far out that damage to case could occur. Carefully remove each shaft from case. Using Spring Remover (09922-85811), remove yoke pin from each shift yoke. DO NOT  allow locating balls and springs to jump out of holes. Remove forks and shaft.
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