Steering Lower Shaft Assembly Removal and Installation: Installation

1. Be sure that front wheels and steering wheel are in straight-ahead position.
2. Align flat part "A" of lower shaft assembly (1) with bolt hole "B" of shaft joint as shown in the figure. Then insert shaft joint (1) into lower shaft assembly (2).
3. Install shaft joint bolt (lower shaft assembly side) to shaft joint (2). Then tighten it by hand.
   Fig 1: Aligning Flat Part Of Lower Shaft Assembly With Bolt Hole

   Courtesy of SUZUKI OF AMERICA CORP.
4. Insert pinion shaft into lower shaft assembly lower joint (2) with slit (1) of lower joint and yellow marks (4) on pinion shaft (5) and gear case (6) aligned. And then install lower shaft assembly lower joint bolt (3) to lower shaft assembly lower joint (2). Tighten it to specified torque.

   Tightening torque 

   Lower shaft assembly lower joint bolt (a): 25 N.m (2.5 kg-m, 18.0 lb-ft) 

   Fig 2: Inserting Pinion Shaft Into Lower Shaft Assembly Lower Joint With Slit Of Lower Joint And Yellow Marks

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install steering shaft joint (1) to steering upper shaft (2) by matching it to marks (3) made before removal.
   NOTE: Be sue that front wheels and steering wheel are in straight-ahead position.
   Fig 3: Installing Steering Shaft Joint To Steering Upper Shaft By Matching It To Marks

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install shaft joint bolt (upper shaft assembly side) (2) to shaft joint (1). Tighten shaft joint bolt (upper shaft assembly side) (2) to specified torque first and then shaft joint bolt (lower shaft assembly side) (3) to specified torque.

Tightening torque 

Steering shaft joint bolt (b): 25 N.m (2.5 kg-m, 18.0 lb-ft) 

Fig 4: Installing Shaft Joint Bolt To Shaft Joint

Courtesy of SUZUKI OF AMERICA CORP.