Input Shaft Disassembly and Assembly: Disassembly

Remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and press.

Fig 1: Removing Input Shaft Right Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Drive out 5th gear spacer (2) and left bearing (3) all at once using puller (4) and hydraulic press.
CAUTION: Stop press work in the middle way and take out 5th gear bush to prevent it from being compressed and then continue to remove bearing with gear.

Fig 2: Driving Out 5th Gear Spacer And Left Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Take out 4th gear, 4th gear needle bearing and high speed synchronizer ring.
Using special tool, remove circlip (1).
NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.

Special tool

(A): 09900-06107

Fig 3: Removing Circlip
Courtesy of SUZUKI OF AMERICA CORP.
Drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) by using puller (4) and hydraulic press.
CAUTION: Make sure to use flat side of puller to avoid causing damage to 3rd gear tooth.

Fig 4: Driving Out High Speed Synchronizer Sleeve & Hub Assembly And 3rd Gear
Courtesy of SUZUKI OF AMERICA CORP.
Take out 3rd gear needle bearing from shaft.
Disassemble synchronizer sleeve & hub assembly.