Main Shaft Assembly

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

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. Don't reuse circlips.

Assemble high speed synchronizer hub (3), sleeve (4), springs (1) and keys(2) according to the following procedure.
1. Slide hub (3) in sleeve (4) so that wider flange side of sleeve (4) and boss side of hub (3) face opposite as shown in the figure, also aligning hub slots with key location teeth of sleeve (4).
2. Insert keys (2) in hub slots with depression side of keys face center of hub (3).
3. Install springs (1) to internal circle of key locations with spring end gaps apart at angles about 120 degrees each other, in order to apply spring tension equally to each key.
NOTE: Do not mix high and low speed synchronizer keys as dimensions are different.

Fig 1: Installing Springs To Internal Circle Of Key Locations
Courtesy of SUZUKI OF AMERICA CORP.
Install synchronizer ring (1) by matching its key slots to keys as shown in the figure.

Fig 2: Installing Synchronizer Ring By Matching Key Slots
Courtesy of SUZUKI OF AMERICA CORP.
Insert 3rd gear (2), needle bearing (3) and high speed sleeve / hub assembly (4) with synchronizer ring to main shaft (1).

Fig 3: Inserting 3rd Gear, Needle Bearing And High Speed Sleeve / Hub Assembly With Synchronizer Ring To Main Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit high speed sleeve / hub assembly (1) with special tool and hydraulic press (2).
Special tool

(A): 09940-53111

Fig 4: Pressing-Fit High Speed Sleeve / Hub Assembly With Special Tool And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.

Select circlip (1) that will make thrust clearance of clutch hub 0.1 mm (0.0039 in) or less and install it.

CIRCLIP THICKNESS SPECIFICATIONS

ID mark	Circlip thickness	ID mark	Circlip thickness
C-1	1.75 - 1.80 mm (0.0689 - 0.0709 in.)	E-1	1.95 - 2.00 mm (0.0768 - 0.0787 in.)
D	1.80 - 1.85 mm (0.0709 - 0.0728 in.)	F	2.00 - 2.05 mm (0.0789 - 0.0807 in.)
D-1	1.85 - 1.90 mm (0.0728 - 0.0748 in.)	F-1	2.05-2.10 mm (0.0807 - 0.0827 in.)
E	1.90-1.95 mm (0.0748 - 0.0768 in.)

Special tool

(B): 09900-06107

Fig 5: Identifying Circlip

Courtesy of SUZUKI OF AMERICA CORP.

After installing circlip, check that 3rd gear turns lightly.
Check 3rd gear (2) thrust clearance by using thickness gauge (1). If clearance is out of specification, repress-fit or replace.
3rd gear thrust clearance

0.10 - 0.25 mm (0.004 - 0.010 in.)

Fig 6: Checking 3rd Gear Thrust Clearance By Using Thickness Gauge
Courtesy of SUZUKI OF AMERICA CORP.
Assemble low speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
1. Slide hub (3) in sleeve (4) with aligning hub slots with key location teeth of sleeve (4).
2. Insert keys (2) in hub slots with depression side of keys (2) face center of hub (3).
3. Install springs (1) to internal circle of key locations with spring end gaps apart at angles about 120 degrees each other, in order to apply spring tension equally to each key.
NOTE: Before installing hub (3), sleeve (4), springs (1) and keys (2) assembly to main shaft, there is no specific installation direction on each component. However, when installing assembly to main shaft, gear side of sleeve (4) should face to forward direction as shown in the figure.

Fig 7: Inserting Keys In Hub Slots
Courtesy of SUZUKI OF AMERICA CORP.
Install synchronizer ring (1) by matching its key slots to keys as shown in the figure.

Fig 8: Installing Synchronizer Ring By Matching Key Slots
Courtesy of SUZUKI OF AMERICA CORP.
Insert 2nd gear (2), needle bearing (3) and low speed sleeve / hub assembly (4) with synchronizer ring to main shaft (1).

Fig 9: Inserting 2nd Gear, Needle Bearing And Low Speed Sleeve / Hub Assembly With Synchronizer Ring To Main Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit low speed sleeve / hub assembly with special tool and hydraulic press (1).
Special tool

(A): 09940-53111

Fig 10: Pressing-Fit Low Speed Sleeve / Hub Assembly With Special Tool And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.
Check 2nd gear thrust clearance referring to "MAIN SHAFT INSPECTION ".
Apply grease to ball (1) and set it to main shaft (3).
Install synchronizer ring (2).

Fig 11: Installing Synchronizer Ring To Main Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing (2), low gear (3) and needle bush (1) to main shaft.
NOTE:
- Check the cut in needle bush and ball are engaged.
- After installation, check the synchronizer ring (4) moves in circumferential direction.
Fig 12: Installing Needle Bearing, Low Gear And Needle Bush To Main Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit main shaft bearing (1) and 5th gear with special tools and hydraulic press (2).
NOTE: Bring bearing so that its groove for circlip is in the rear.

Special tool

(C): 09940-51710

or (C): 09925-18010

Fig 13: Pressing-Fit Main Shaft Bearing And 5th Gear With Special Tools And Hydraulic Press
Courtesy of SUZUKI OF AMERICA CORP.

Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 in.) or less and install it.

CIRCLIP THICKNESS SPECIFICATIONS

ID mark	Circlip thickness	ID mark	Circlip thickness
A	2.67 - 2.72 mm (0.1051-0.1071 in.)	G	3.03 - 3.08 mm (0.1193-0.1213 in.)
B	2.73 - 2.78 mm (0.1075 - 0.1094 in.)	H	3.09 - 3.14 mm (0.1217-0.1236 in.)
C	2.79 - 2.84 mm (0.1098-0.1118 in.)	J	3.15-3.20 mm (0.1240-0.1260 in.)
D	2.85 - 2.90 mm (0.1122-0.1142 in.)	K	3.21 - 3.26 mm (0.1264-0.1283 in.)
E	2.91 - 2.96 mm (0.1146-0.1165 in.)	L	3.27 - 3.32 mm (0.1287-0.1307 in.)
F	2.97 - 3.02 mm (0.1169-0.1189 in.)

Fig 14: Identifying Circlip

Courtesy of SUZUKI OF AMERICA CORP.

Check low gear clearance referring to "INPUT SHAFT INSPECTION ".