Input Shaft Disassembly and Assembly: Assembly

Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
If synchronizer parts need to be repaired, check clearance "a" between ring (2) and gear (1), each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Clearance "a" between synchronizer ring and gear

Standard: 1.0 - 1.4 mm (0.039 - 0.055 in.)

Service limit: 0.5 mm (0.019 in.)

Fig 1: Checking Clearance
Courtesy of SUZUKI OF AMERICA CORP.
To ensure lubrication of input shaft (1), air blow oil holes (2) and make sure that they are free from any obstruction.

Fig 2: Blowing Out Oil Holes
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Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure.
NOTE:
- No specific direction is assigned to high speed synchronizer sleeve or each key but it is assigned as assembly.
- Size of high speed synchronizer sleeve, hub, keys and springs is between those of low speed and 5th speed ones.
Synchronizer key installation position

"A" = "B"

Fig 3: Fitting High Speed Synchronizer Sleeve, Keys And Springs To Hub
Courtesy of SUZUKI OF AMERICA CORP.
Drive in right bearing (1) to input shaft (2) using special tool and hammer.
Special tool

(A): 09951-16080

Fig 4: Driving In Right Bearing
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Install 3rd gear needle bearing, apply oil to it, then install 3rd gear (2) and synchronizer ring (3).
Drive in high speed sleeve & hub assembly (4) by using special tool and hammer.
NOTE:
- While press-fitting sleeve & hub, make sure that synchronizer ring key slots are aligned with keys in sleeve & hub assembly.
- Check free rotation of 3rd gear after press-fitting sleeve & hub assembly.
- Synchronizer rings for 3rd and 4th are identical.
Special tool

(B): 09913-84510

Fig 5: Driving In High Speed Sleeve & Hub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install circlip (1), needle bearing (2), apply oil to bearing, then install synchronizer ring (3) and 4th gear (4).
CAUTION: Confirm that circlip is installed in groove securely.

Fig 6: Installing Circlip, Needle Bearing, Synchronizer Ring And 4th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit left bearing (2) by using special tool and hammer.
Special tool

(A): 09913-70123
Using the same special tool, drive in 5th gear spacer (1).
CAUTION: To prevent 5th gear spacer from being distorted because of excessive compression, do not press-fit it with left bearing at once.

Fig 7: Driving In 5th Gear Spacer
Courtesy of SUZUKI OF AMERICA CORP.