Manual Transmission: 5B-11
Assembly
NOTE
When reassembling the transmission gears,
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. Refer to “Transmission
Construction” (Page 5B-9).
CAUTION
!
• Never reuse a snap ring. After a snap ring
has been removed from the 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 the groove and
securely fitted.
NOTE
• Rotate the bearing by hand to inspect if
there is any abnormal noise and for
smooth rotation. Replace the bearing if
there is anything unusual.
• Before installing the gears, apply engine
oil to the driveshaft and countershaft.
• Before installing the oil seal, apply grease
to the oil seal lip.
: Grease 99000–25010 (SUZUKI SUPER
GREASE “A” or equivalent)
• When installing a new snap ring (1), pay attention to
its direction. Fit it to the side where the thrust is as
shown in the figure.
Driveshaft
• When installing the gear bushings onto the driveshaft,
align the shaft oil holes “A” with the bushing oil hole
“B”.
Countershaft
• Install the countershaft bearing (1) using a hydraulic
press and special tool.
Special tool
(A): 09913–70210 (Bearing installing set (10
– 75 Φ))
“A”: Thrust “B”: Sharp edge
1
“A”
“B”
I649G1520049-02
“A”
“B”
I947H1520064-01
“A”
“B”
I947H1520065-01
1
1
(A)
I947H1520066-02
Manuals by Motomatrix / The Solution For Lost Motorcycle Coded Keys
email: info@motomatrix.co.uk / www.motomatrix.co.uk
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