LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2002 >> XL-7 Plus >> Repair and Diagnosis >> External Pages >> Different car >> Section 86 (Overhaul - M/T) >> Repair Instructions >> Main Shaft Disassembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Main Shaft Disassembly

WARNING: This page is about a different car, the 2004 Suzuki XL-7. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove circlip (1) from main shaft (2) using flat head screwdrivers or the like.
    Fig 1: Removing Circlip From Main Shaft
    G00761714Courtesy of SUZUKI OF AMERICA CORP.
  2. Pull out 5th gear (1), main shaft bearing (2), low gear thrust washer (3) and low gear (4) with bearing puller (5) and hydraulic press (6).
    Fig 2: Pulling Out 5th Gear
    G00761715Courtesy of SUZUKI OF AMERICA CORP.
  3. Remove low gear synchronizer inner ring (1), synchronizer cone ring (2), synchronizer outer ring (3), pin (4), needle bearing (5) and spacer (6).
    Fig 3: Removing Low Gear Synchronizer Inner Ring, Synchronizer Cone Ring, Synchronizer Outer Ring, Pin, Needle Bearing & Spacer
    G00761716Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove circlip (9) and pull out 2nd gear (2), needle bearing (5), 2nd gear synchronizer outer ring (6), cone ring (7), inner ring (8) and low speed synchronizer sleeve/hub assembly (1) together using puller (3) and hydraulic press (4).
    Fig 4: Removing Circlip & Pulling Out 2nd Gear, Needle Bearing, 2nd Gear Synchronizer Outer Ring, Cone Ring, Inner Ring & Low Speed Synchronizer Sleeve/Hub Assembly
    G00761717Courtesy of SUZUKI OF AMERICA CORP.
  5. Remove circlip (9) from front part of main shaft and pull out 3rd gear (1), needle bearing (8), 3rd gear synchronizer outer ring (5), cone ring (6), inner ring (7) and high speed synchronizer sleeve/hub assembly (2) together using puller (3) and hydraulic press (4).
    Fig 5: Removing Circlip From Front Part Of Main Shaft & Pulling Out 3rd Gear, Needle Bearing, 3rd Gear Synchronizer Outer Ring, Cone Ring, Inner Ring & High Speed Synchronizer Sleeve/Hub Assembly
    G00761718Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove high speed synchronizer sleeve from high speed synchronizer hub (2).
  7. Remove keys (1) and springs from high speed synchronizer hub (2) using flat head screwdriver (3) or the like as shown in the figure.
    Fig 6: Removing Keys & Springs From High Speed Synchronizer Hub
    G00761719Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove low speed synchronizer sleeve/hub in similar manner as steps  6 ) and  7 .
scientia non olet · About LEMON Manuals