New circlip must be installed.

* When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft.

* After installing a circlip, always insure that it is completely seated in its groove and securely fitted.

NOTE:

In reassembling the transmission gears, attention must be given to the locations and positions of washers and circlips. The cross sectional view given here will serve as a reference for correctly mounting the gears, washers and circlips. (Refer to page 3-43.)

• When installing a new circlip CD, pay attention to the direc­ tion of the circlip. Fit it to the side where the thrust is as

shown in the illustration.

Thrust

iP.w ckcUp

Sharp edge

•

NOTE:

* Before reassembling the 2nd drive gear, apply its internal surface with THREAD LOCK SUPER " 1303" and install it so that the length as shown in the illustration.

* After installing the 2nd drive gear, check that Top drive gear spins smoothly by moving it with your fingers.

* This procedure may be performed only twice before shaft replacement is required.

• Apply grease to each oil seal lip and install them onto the driveshaft and countershaft.

(For U.S.A. model)

99000-25030: SUZUKI SUPER GREASE " A"

(For the other models)

99000-25010: SUZUKI SUPER GREASE " A"

®

• When i nsta l l i ng the 3rd/4th d riven gear bushi ng onto the shaf t, a l ign the shaf t oi l hole CD with the bushi ng oi l hol e ®·