Main Shaft Disassembly

After removing needle bearing for input shaft at the front end of main shaft, pull out high speed sleeve from its hub (3) and remove 3 synchronizer keys.
Remove circlip in front of hub (3) and pull off hub (3) with special tool, then take out synchronizer springs.
Special tool

(A): 09913-61510
Remove 3rd synchronizer ring (2), 3rd gear (1) and needle bearing.
NOTE: High speed sleeve-hub assembly, synchronizer ring and 3rd gear (1) can be removed all at once by using puller and hydraulic press.

Fig 1: Removing Front Main Shaft Circlip & Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip in the rear part of main shaft (1) and pull off rear bearing (2) with bearing puller (3) and press.

Fig 2: Removing Rear Main Shaft Circlip & Rear Main Shaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove thrust washer and steel ball and then remove 5th gear, synchronizer ring and needle bearing.
Pull out reverse sleeve from its hub (2) and remove 3 synchronizer keys.
Remove circlip and pull off reverse hub (2) from main shaft (1) with bearing puller (3) and press, then take out synchronizer springs.
NOTE: It is also possible to remove reverse sleeve-hub as assembly and reverse gear all at once by using puller and press, after removing circlip.

Fig 3: Removing Circlip & Reverse Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove main shaft reverse gear and needle bearing by hand.
Using bearing puller (4) and press, remove reverse gear bush (2) and bearing washer (3) from main shaft (1).
NOTE: During above work, watch out for steel ball which will come out from inside of washer so as not to lose it.

CAUTION: Do not attempt to pull out bearing, washer (3) and bush (2) all together at once. Steel ball would stop bearing and cause damage to it.

Fig 4: Removing Reverse Gear Bush & Bearing Washer
Courtesy of SUZUKI OF AMERICA CORP.
Pull off bearing (1) with bearing puller (2) and press.

Fig 5: Removing Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the following in that order: bearing washer, steel ball, low gear, low synchronizer, needle bearing and low gear bush (1).
Using bearing puller (4) and press, pull out low speed sleeve and hub assembly (2), 2nd gear (3) and 2nd synchronizer ring all together.
NOTE: If bush can't be pulled out by hand at Step 11), pull off sleeve and hub together by using press.

Fig 6: Removing Low Speed Sleeve, Hub Assembly, 2nd Gear & 2nd Synchronizer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove sleeve from hub and then take off synchronizer keys and springs.