Not sure which gear locking balls you mean but am sure to find out when I discover what you meant at the wrong time.
the gears are pulled 1 by 1 if not these 2 balls LOCK. off counter shaft.
step 22 here
http://www.fixkick.com/tranny/5speed-rebuild.html
or photo here.
http://www.fixkick.com/tranny/images/magic.jpg
The weather here and my resolve are finally aligned (and have parts). Got seats out, console, and now working on shifter removal.
Wondering: does it matter what gear I set each to for removal? NO, (with lid off , the counter shaft , just lifts out, there are no gears to set once lifted but neutral would be good. keeping the syncrho hubs, contained.
I guess I can be taking the muffler off while I worry about it.
Removing the seat, and setting in back, I caught a rail in my brittle back window, so there's a replacement or new top job for after. Until then, duct tape city.
ouch.
rc
[/quote]
the only tricks are the 2 tiny locking balls
and on assembly getting the Gaps right, measured as you pull counter out of case, just before.
that gap issues is because you dont have the rare suzuki special tool to set them, last.
mine measured 0.005" this free play gap, so on assembly it put it back to that much. see gap 1
http://www.fixkick.com/tranny/5thGear.JPG
the gap is here, at bearing 8, if set wrong, 8 binds, (too far set forward) if too far rear set, then bearing 11 will not fit and snap 12 will not fit.
this is the only calibration step.
the special tool sets bearing 8, exactly. but we dont need it. use feeler gauge as the 1st act. lid off.
the gears are pulled 1 by 1 if not these 2 balls LOCK. off counter shaft.
step 22 here
http://www.fixkick.com/tranny/5speed-rebuild.html
or photo here.
http://www.fixkick.com/tranny/images/magic.jpg
The weather here and my resolve are finally aligned (and have parts). Got seats out, console, and now working on shifter removal.
Wondering: does it matter what gear I set each to for removal? NO, (with lid off , the counter shaft , just lifts out, there are no gears to set once lifted but neutral would be good. keeping the syncrho hubs, contained.
I guess I can be taking the muffler off while I worry about it.
Removing the seat, and setting in back, I caught a rail in my brittle back window, so there's a replacement or new top job for after. Until then, duct tape city.
ouch.rc
[/quote]
the only tricks are the 2 tiny locking balls
and on assembly getting the Gaps right, measured as you pull counter out of case, just before.
that gap issues is because you dont have the rare suzuki special tool to set them, last.
mine measured 0.005" this free play gap, so on assembly it put it back to that much. see gap 1
http://www.fixkick.com/tranny/5thGear.JPG
the gap is here, at bearing 8, if set wrong, 8 binds, (too far set forward) if too far rear set, then bearing 11 will not fit and snap 12 will not fit.
this is the only calibration step.
the special tool sets bearing 8, exactly. but we dont need it. use feeler gauge as the 1st act. lid off.
http://www.fixkick.com