Mainshaft Disassembly and Assembly: Disassembly

Remove the mainshaft bearing using the universal bearing puller J-22912-01.

Fig 1: Removing The Mainshaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the snap ring.

Fig 2: Removing The Snap Ring
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Remove the first gear, the flat-type first-gear needle bearing, and the mainshaft wear plate.

Fig 3: Removing The First Gear
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Remove the synchronizer hub sleeve that contains the synchronizer spring.
Remove the outer blocking ring.

Fig 4: Removing The Outer Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the keys from the first-second synchronizer gear.

Fig 5: Removing The Keys
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Remove the barrel-type first-gear needle bearing.

Fig 6: Removing The Barrel-Type Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the snap ring and the washer.

Fig 7: Removing The Snap Ring & Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first-second synchronizer gear from the mainshaft.

Fig 8: Removing The First-Second Synchronizer Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first-second gear blocking ring.

Fig 9: Removing The First-Second Gear Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the second gear using the universal bearing puller J-22912-01.

Fig 10: Removing The Second Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the second-gear needle bearing.

Fig 11: Removing The Second-Gear Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the ring and the thrust washer.

Fig 12: Removing The Ring & Thrust Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the third gear and the synchronizer blocking ring.

Fig 13: Remove The Third Gear
Courtesy of SUZUKI OF AMERICA CORP.
Separate the synchronizer blocking ring from the third gear.

Fig 14: Separating The Synchronizer Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the third-gear needle bearing from the mainshaft.

Fig 15: Removing The Third-Gear Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the synchronizer sleeve containing the keys and the spring.

Fig 16: Removing The Synchronizer Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Remove the snap ring and the washer from the mainshaft.

Fig 17: Removing The Snap Ring & Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the third-fourth synchronizer gear containing the synchronizer spring.

Fig 18: Removing The Third-Fourth Synchronizer Gear
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Remove the fourth-gear assembly.

Fig 19: Removing The Fourth-Gear Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Separate the synchronizer blocking ring from the fourth gear.

Fig 20: Separating The Synchronizer Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the fourth-gear needle bearing, the ring, and the thrust washer.

Fig 21: Removing The Fourth-Gear Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft bearing.

Fig 22: Removing The Mainshaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.