Countershaft and Reverse Idle Gear Disassembly and Assembly: Assembly

1. Fit sleeve (4) to counter shaft 5th gear (3), place 3 synchronizer keys (2) in it and then set synchronizer springs (1). Refer to figure for proper installing direction of gear, sleeve and springs. Also, note that key has specific installing direction.
   Fig 1: Installing Gear, Sleeve And Springs

   Courtesy of SUZUKI OF AMERICA CORP.
2. Set inner race (2) to countershaft front bearing (1) and press-fit bearing with press and special tool.
   NOTE: When installing bearing, bring it so that its groove for circlip is in the front.

   Special tool 

   (A): 09940-54950 

   Fig 2: Installing Countershaft Front Bearing

   Courtesy of SUZUKI OF AMERICA CORP.
3. Select circlip that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it.

Circlip thickness specification 

Fig 3: Circlip Thickness Specification Chart

Courtesy of SUZUKI OF AMERICA CORP.

Special tool 

(B): 09900-06107 

Fig 4: Installing Circlip

Courtesy of SUZUKI OF AMERICA CORP.