Transmission installation

Install the transmission in the reverse order of removal.

Pay attention to the following points:

Bearing and oil seal

Caution replace the removed bearings and oil seals with new ones.

• Install the driveshaft left bearing oil seal into the retainer using the special tool.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ф))

• Install the driveshaft left bearing with the special tool.

Note the stamped mark side of the driveshaft left bearing faces outside.

Special tool (a):
09913–70210 (bearing installing set (10 – 75Фö))

• Install the gearshift shaft bearings (1) and (2) with the special tool.

Note the stamped mark side of the gearshift shaft bearing faces outside.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ф))

• Install the gearshift shaft oil seal (3) with the special tool.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ф))

• Apply grease to the oil seal lip.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

• Install the gearshift cam bearing with the special tool.

Special tool (a): 09913–70210 (bearing
installing set (10 – 75 Ф))

Driveshaft assembly

• Put the driveshaft assembly (1) into the lower crankcase.
• Install the driveshaft right bearing assembly (2).
• Apply thread lock to the bolts and tighten them to the specified torque.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent) Tightening torque driveshaft right bearing case bolt (a): 12 N·m

• Install the dowel pin.
• Apply grease to the o-ring and install the driveshaft left bearing case (3).

Caution replace the o-ring with a new one.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

• Apply thread lock to the bolts and tighten them to the specified torque.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent) Tightening torque driveshaft left bearing case bolt (b): 12 N·m

• Apply grease to the oil seal lip and o-ring.

Caution replace the o-ring with a new one.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

• Install the oil seal retainer (4).
• Apply thread lock to the screws and tighten them to the specified torque.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent) Tightening torque driveshaft oil seal retainer screw (c): 12 N·m

• Apply grease to the o-ring (5) and install it to the driveshaft.

Caution replace the o-ring with a new one.

: Grease 99000–25010 (suzuki
super grease “a” or equivalent)

• Install the spacer (6).

Gearshift cam and gearshift fork

• Install the gearshift forks (1) as shown.

• Install the gearshift cam (2) with the bearing fitted.

• With engaging each fork end to the cam groove, insert the fork shaft (3).
• Apply thread lock to the screws and tighten them to the specified torque.

: Thread lock cement
99000–32110 (thread lock cement super “1322” or equivalent) Tightening torque gearshift cam bearing retainer screw (a): 10 N·m

Countershaft

• Install the c-ring (1) and bearing pin (2) to the upper crankcase.

• Install the countershaft assembly to the upper crankcase.

Note

align the c-ring with the groove of bearing and the bearing pin with the indent on the bearing.

• Turn the bearing and set the bearing dowel pin in position.

• Install the clutch push rod oil seal (3).
• Install the gearshift fork/gearshift shaft (4) and gearshift shaft plug (5).