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Main Shaft Assembly

NOTE:
  • Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear
  • Use new circlips on shaft for installation. DO NOT reuse circlips.
  1. Assemble high speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
    1. Install synchronizer springs (1) and synchronizer keys (2) to high speed synchronizer hub (3) as shown in the figure.
    2. Slide hub (3) in sleeve (4) so that chamfered side of sleeve (4) and small diameter boss side of hub (3) face opposite as shown in the figure, also aligning hub slots with key location teeth of sleeve (4).
    Fig 1: Assembling High Speed Synchronizer Hub
    G01326219Courtesy of SUZUKI OF AMERICA CORP.
  2. Assemble 3rd gear (1), synchronizer inner ring (2), synchronizer cone ring (4) and synchronizer outer ring according to the following procedure.
    1. Install the synchronizer inner ring (2) to 3rd gear (1).
    2. Install synchronizer cone ring (4) to 3rd gear (1).
      NOTE: Fit protrusion (5) of synchronizer cone ring (4) into groove (3) of 3rd gear.
      Fig 2: Assembling 3rd Gear
      G01326220Courtesy of SUZUKI OF AMERICA CORP.
    3. Install synchronizer outer ring (1) to 3rd gear (2).
      Fig 3: Installing Synchronizer Outer Ring To 3rd Gear
      G01326221Courtesy of SUZUKI OF AMERICA CORP.
    4. Align protrusion (1) of synchronizer outer ring into slot (2) of synchronizer hub, and then attach high speed synchronizer sleeve and hub assembly to 3rd gear (3). Also align protrusion (4) of synchronizer inner ring and dent (5) of high speed synchronizer hub.
    Fig 4: Aligning Protrusion Of Synchronizer Outer Ring Into Slot Of Synchronizer Hub
    G01326222Courtesy of SUZUKI OF AMERICA CORP.
  3. Install needle bearing (2) to main shaft (1) and press fit 3rd gear high speed synchronizer sleeve and hub assembly (3), which was assembled in step a) through d), to main shaft (1) using special tool and hydraulic press.

    Special tool 

    1. (A):  09940-53111
    Fig 5: Installing Needle Bearing To Main Shaft
    G01326223Courtesy of SUZUKI OF AMERICA CORP.
  4. Select circlip (1) that will make thrust clearance of high speed synchronizer hub 0.1 mm (0.0039 in) or less and install it.
    Fig 6: Circlip Thickness Specifications Table
    G01326224Courtesy of SUZUKI OF AMERICA CORP.

    Special tool 

    1. (B):  09900-06107
    Fig 7: Measuring Thrust Clearance Of High Speed Synchronizer
    G01326225Courtesy of SUZUKI OF AMERICA CORP.
  5. After installing circlip, check that 3rd gear turns lightly.
  6. Check 3rd gear (2) thrust clearance using thickness gauge (1). If clearance is out of specification, repress-fit or replace.
    1. 3rd gear thrust clearance:  0.10 - 0.25 mm (0.004 - 0.010 in.)
    Fig 8: Checking 3rd Gear Thrust Clearance
    G01326226Courtesy of SUZUKI OF AMERICA CORP.
  7. Assemble low speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
    1. Install synchronizer springs (1) and synchronizer keys (2) to low speed synchronizer hub (3) as shown in the figure.
    2. Slide low speed synchronizer hub (3) in sleeve (4) so that flange side of sleeve (4) and small diameter boss side of hub (3) face opposite as shown the figure, also aligning hub slots with key location teeth of sleeve (4).
    Fig 9: Assembling Low Speed Synchronizer Hubs
    G01326227Courtesy of SUZUKI OF AMERICA CORP.
  8. Assemble 2nd gear (1), synchronizer inner ring (2), synchronizer cone ring (3) and synchronizer outer ring according to the following procedure.
    1. Install synchronizer inner ring (2) to 2nd gear (1).
    2. Install synchronizer cone ring (4) to 2nd gear (1).
      NOTE: Fit protrusion (4) of synchronizer cone ring (4) into groove (3) of 2nd gear.
      Fig 10: Assembling 2nd Gear
      G01326228Courtesy of SUZUKI OF AMERICA CORP.
    3. Install synchronizer outer ring (1) to 2nd gear (2).
      Fig 11: Installing Synchronizer Outer Ring To 2nd Gear
      G01326229Courtesy of SUZUKI OF AMERICA CORP.
    4. Install 2nd gear (3), fitting slot (1) of low speed synchronizer hub in protrusion (2) of synchronizer outer ring as shown in the figure. Also align protrusion (4) of synchronizer inner ring and dent (5) of low speed synchronizer hub.
    Fig 12: Installing 2nd Gear
    G01326230Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the needle bearing to the 2nd gear, then as the figure shows press fit 2nd gear low speed synchronizer sleeve and hub assembly (1), which was assembled in step  a through  d , into main shaft (2) using special tool. Press- fit low speed sleeve and hub assembly with special tool and hydraulic press (3).

    Special tool 

    1. (A):  09944-78210
    Fig 13: Installing Needle Bearing To 2nd Gear
    G01326231Courtesy of SUZUKI OF AMERICA CORP.
  10. Select circlip (1) that will make thrust clearance of low speed synchronizer hub 0.1 mm (0.0039 in.) or less and install it.
    Fig 14: Circlip Thickness Specifications Table
    G01326232Courtesy of SUZUKI OF AMERICA CORP.

    Special tool 

    1. (A):  09900-06107
    Fig 15: Measuring Thrust Clearance Of Low Speed Synchronizer Hub
    G01326233Courtesy of SUZUKI OF AMERICA CORP.
  11. Check 2nd gear thrust clearance, referring to MAIN SHAFT ASSEMBLY  .
  12. Install spacer (1) and needle bearing (2) to main shaft (3).
    Fig 16: Installing Spacer & Needle Bearing To Main Shaft
    G01326234Courtesy of SUZUKI OF AMERICA CORP.
  13. Install synchronizer outer ring (1) to low speed synchronizer hub (2).
    NOTE: Fit protrusion (3) of synchronizer outer ring (1) into groove (4) of low speed synchronizer hub (2).
    Fig 17: Installing Synchronizer Outer Ring To Low Speed Synchronizer Hub
    G01326235Courtesy of SUZUKI OF AMERICA CORP.
  14. Install synchronizer cone ring (1) and synchronizer inner ring (2).
    NOTE: Fit protrusion (3) of synchronizer inner ring (2) into dent (4) of low speed synchronizer hub (5).
    Fig 18: Installing Synchronizer Cone Ring & Synchronizer Inner Ring
    G01326236Courtesy of SUZUKI OF AMERICA CORP.
  15. Install low gear (1) to main shaft (2).
    NOTE:
    • Fit protrusion (3) of synchronizer cone ring (5) into groove (4) of low gear (1).
    • After installation, check synchronizer outer ring (5) moves in circumferential direction.
    Fig 19: Installing Low Gear To Main Shaft
    G01326237Courtesy of SUZUKI OF AMERICA CORP.
  16. Install pin (1) and low gear thrust washer (2) to main shaft.
    NOTE: Check the cut in low gear thrust washer and pin are engaged.
    Fig 20: Installing Pin & Low Gear Thrust Washer To Main Shaft
    G01326238Courtesy of SUZUKI OF AMERICA CORP.
  17. Press-fit main shaft bearing (1) and 5th gear (3) with special tool and hydraulic press (2).
    NOTE:
    • Bring bearing so that its groove for circlip is in the rear.
    • Bring 5th gear (3) so that its small diameter boss "a" is in the rear.

    Special tool 

    1. (C):  09940-51710
    Fig 21: Press-Fitting Main Shaft Bearing & 5th Gear
    G01326239Courtesy of SUZUKI OF AMERICA CORP.
  18. Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it.
    Fig 22: Circlip Thickness Specifications Table
    G01326240Courtesy of SUZUKI OF AMERICA CORP.
    Fig 23: Measuring Thrust Clearance
    G01326241Courtesy of SUZUKI OF AMERICA CORP.
  19. Check low gear clearance referring to MAIN SHAFT ASSEMBLY  .
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