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Component Disassembly & Reassembly: MAINSHAFT: Disassembly

  1. Remove input shaft from mainshaft. Remove circlip at high speed hub assembly using Circlip Remover (Geo J34757). See Figure . Using Bearing Remover (Geo J22912-01 or Suzuki 09913-61510), press off high speed sleeve-hub assembly, synchronizer ring and 3rd gear. Remove 3rd gear needle bearing and circlip at rear of mainshaft.
  2. Press off rear bearing using bearing remover. Remove 5th gear washer, steel ball, 5th gear, 5th gear synchronizer ring and 5th gear needle bearing. Remove circlip at reverse sleeve-hub assembly. Press off reverse sleeve-hub assembly using bearing remover.
  3. Remove reverse gear, reverse gear needle bearing, bearing washer and steel ball. Press off reverse gear bushing using bearing remover and press off mainshaft bearing. Remove bearing washer, steel ball, low gear, low gear synchronizer and low gear needle bearing.
  4. Press off low gear bushing, low speed sleeve-hub assembly, 2nd gear and 2nd gear synchronizer using bearing remover. Remove 2nd gear needle bearing.
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