Main Shaft Assembly

NOTE:

Before assembly, wash each part and apply specified gear oil to sliding faces of bearing and gear.
Use new circlips on shaft for reinstallation. Don't reuse used circlips.

Fig 1: Main Shaft & Main Shaft Components
Courtesy of SUZUKI OF AMERICA CORP.

Fit sleeve to low speed hub (1), place 3 synchronizer keys (4) in it and set synchronizer spring (3). Refer to figure for proper installing direction of hub (1), sleeve (2) and springs (3).
Synchronizer key (4) has no specific direction for installation.

NOTE: When installing each synchronizer spring, insert its hooked end to hub hole and put it toward right.

Fig 2: Identifying Low Speed Hub, Synchronizer Keys, Synchronizer Spring, Sleeve Thick / Thin Sides & Springs
Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing (2), 2nd gear (3) and 2nd synchronizer ring to main shaft (1).

Fig 3: Identifying Needle Bearing, 2nd Gear & 2nd Synchronizer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit sleeve and hub assembly (2) onto main shaft (1) with press (3).
Special tool

(A): 09927-08210

Fig 4: Installing Sleeve & Hub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Insert low gear bush (1) and set synchronizer ring (3), needle bearing (2) and low gear (4).

Fig 5: Identifying Low Gear Bush, Synchronizer Ring, Needle Bearing & Low Gear
Courtesy of SUZUKI OF AMERICA CORP.
Set steel ball (1) and washer (2).

Fig 6: Identifying Low Gear, Steel Ball & Washer
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool and press, press-fit bearing (1).
Special tool

(B): 09925-18011

Fig 7: Installing Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Fit sleeve (4) to reverse hub (3), place 3 synchronizer keys (2) in it and then set synchronizer springs (1). Refer to the figure for proper installing direction of hub (3), sleeve (4) and springs (1). Also, note that key (2) has specific installing direction.

Fig 8: Identifying Sleeve, Reverse Hub, Synchronizer Keys & Synchronizer Springs
Courtesy of SUZUKI OF AMERICA CORP.
Set steel ball and bearing washer (2) and insert reverse gear bush (3), needle bearing (4) and reverse gear (5).

Fig 9: Identifying Bearing, Bearing Washer With Steel Ball, Reverse Gear Bush, Needle Bearing & Reverse Gear
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit reverse sleeve and hub assembly (1) with special tool and press.
Special tool

(B): 09925-18011

Fig 10: Installing Reverse Sleeve & Hub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
After setting large circlip (2), install 5th speed synchronizer ring, needle bearing, 5th gear (4), steel ball (5) and washer (6).
NOTE: Washer should be installed with its oil slot side facing gear.

Fig 11: Identifying Sleeve, Hub Assembly, Large Circlip (2), Install 5th Speed Synchronizer Ring, Needle Bearing, 5th Gear, Steel Ball & Washer
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit bearing (1) with special tool and press.
Special tool

(A): 09925-18011

Fig 12: Installing Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Fit small circlip.
Fit sleeve (4) to high speed hub (3), place 3 synchronizer keys (2) and set synchronizer springs (1) as shown in the figure.
Neither sleeve nor key has specific installing direction.

Fig 13: Identifying Sleeve, High Speed Hub, Synchronizer Keys & Synchronizer Springs
Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing, 3rd gear (3) and 3rd synchronizer ring (2). Then using special tool (C) and press, press-fit high speed sleeve and hub assembly (1) onto shaft.
Special tool

(C): 09913-84510

Fig 14: Installing Needle Bearing, 3rd Gear, 3rd Synchronizer Ring, High Speed Sleeve & Hub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Fit large circlip.
Install needle bearing.