Gearshift

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Removal

Remove the shift pedal. See the Gearshift Pedal topic for more information.

Remove the snap ring from the shift shaft with snap ring pliers. Remove the washer from the shift shaft.

Remove the clutch basket. See the Clutch Removal topic for more information.

Slide out the gear shift shaft.

Inspect the gearshift shaft for wear and damage. Inspect the gearshift shaft seal for wear and leaks. Replace the seal as needed.

Loosen the gearshift retainer plate screws with an #3 Phillips impactscrewdriver.

Remove the lower gearshift retainer plate screws and plate.

Remove the upper gearshift retainer plate screws and plate.

Place a rag below the gearshift cam driven gear to prevent parts or debris from falling down into the engine. Remove the gearshift cam driven gear from the shift drum.

Do not loose the gearshift cam driven gear components.

Installation

The gearshift shaft seal must be replaced if it is removed. Coat the lips of the new oil seal in Suzuki Super Grease "A". Drive the seal in with a pinion bearing installer or suitable tool.

Special Tool- Pinion Bearing Installer: 09943-88211

Suzuki Super Grease "A" :099000-25030

Assemble the gearshift cam driven gear. The thick sections of the shift pawls should face out from the engine.

Place the gearshift cam driven gear on the shift drum.

Apply a small amount of blue Loctite to the threads of the four gearshift retainer plate screws. Install the upper gearshift retainer plate. Tighten the screws securely with a #3 Phillips screwdriver.

Install the lower gearshift retainer plate. Tighten the screws securely with a #3 Phillips screwdriver.

Install the gearshift shaft so that the middle tooth on the gearshift cam driven gear lines up with the middle gap on the gearshift shaft gear.

Install the washer and snap ring onto the shift shaft. Fit the snap ring into its groove with snap ring pliers.

Install the clutch. See the Clutch Installation topic for more information.

Install the shift pedal. See the Gearshift Pedal topic for more information.

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