Mainshaft Disassembly and Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

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

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

Fig 2: Removing Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the first gear, the flat-type first-gear needle bearing, and the mainshaft wear plate.

Fig 3: Removing First Gear, Flat-Type First-Gear Needle Bearing, And Mainshaft Wear Plate
Courtesy of SUZUKI OF AMERICA CORP.
Remove the synchronizer hub sleeve that contains the synchronizer spring.
Remove the outer blocking ring.

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

Fig 5: Removing Keys From First-Second Synchronizer Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the barrel-type first-gear needle bearing.

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

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

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

Fig 9: Removing 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 Second Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove the second-gear needle bearing.

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

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

Fig 13: Removing Third Gear And Synchronizer Blocking Ring
Courtesy of SUZUKI OF AMERICA CORP.
Separate the synchronizer blocking ring from the third gear.

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

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

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

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

Fig 18: Removing Third-Fourth Synchronizer Gear Containing Synchronizer Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove the fourth-gear assembly.

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

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

Fig 21: Removing Fourth-Gear Needle Bearing, Ring, And Thrust Washer
Courtesy of SUZUKI OF AMERICA CORP.
Remove the mainshaft bearing.

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