Main Shaft Disassembly

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

Remove circlip (1) from main shaft (2) using flat head screwdrivers or the like.

Fig 1: Removing Circlip From Main Shaft Using Flat Head Screwdriver
Courtesy of SUZUKI OF AMERICA CORP.
Pull out 5th gear (1), main shaft bearing (2), low gear thrust washer (3) and low gear (4) with bearing puller (5) and hydraulic press (6).

Fig 2: Pulling Out 5th Gear, Main Shaft Bearing, Low Gear Thrust Washer And Low Gear
Courtesy of SUZUKI OF AMERICA CORP.
Remove low gear synchronizer inner ring (1), synchronizer cone ring (2), synchronizer outer ring (3), pin (4), needle bearing (5) and spacer (6).

Fig 3: Removing Low Gear Synchronizer Inner Ring, Synchronizer Cone Ring, Synchronizer Outer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (9) and pull out 2nd gear (2), needle bearing (5), 2nd gear synchronizer outer ring (6), cone ring (7), inner ring (8) and low speed synchronizer sleeve/hub assembly (1) together using puller (3) and hydraulic press (4).

Fig 4: Pulling Out 2nd Gear, Needle Bearing, 2nd Gear Synchronizer Outer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Remove circlip (9) from front part of main shaft and pull out 3rd gear (1), needle bearing (8), 3rd gear synchronizer outer ring (5), cone ring (6), inner ring (7) and high speed synchronizer sleeve/hub assembly (2) together using puller (3) and hydraulic press (4).

Fig 5: Removing Circlip From Front Part Of Main Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Remove high speed synchronizer sleeve from high speed synchronizer hub (2).
Remove keys (1) and springs from high speed synchronizer hub (2) using flat head screwdriver (3) or the like as shown in the figure.

Fig 6: Removing High Speed Synchronizer Sleeve From High Speed Synchronizer Hub
Courtesy of SUZUKI OF AMERICA CORP.
Remove low speed synchronizer sleeve/hub in similar manner as steps 6) and 7).