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
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Remove the snap ring.

Fig 2: Identifying Snap Ring
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Remove the 1st gear, the flat-type 1st-gear needle bearing, and the mainshaft wear plate.

Fig 3: Removing 1st Gear, Flat-Type 1st-Gear Needle Bearing, And Mainshaft Wear Plate
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Remove the synchronizer hub sleeve that contains the synchronizer spring.
Remove the outer blocking ring.

Fig 4: Removing Outer Blocking Ring
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Remove the keys from the 1st - 2nd synchronizer gear.

Fig 5: Identifying Keys Onto First-Second Synchronizer Gear
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Remove the barrel-type 1st-gear needle bearing.

Fig 6: Identifying Barrel-Type First-Gear Needle Bearing
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Remove the snap ring and the washer.

Fig 7: Identifying Snap Ring And Washer
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Remove the 1st - 2nd synchronizer gear from the mainshaft.

Fig 8: Removing 1st - 2nd Synchronizer Gear From Mainshaft
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Remove the 1st - 2nd gear blocking ring.

Fig 9: Identifying First-Second Gear Blocking Ring
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Remove the 2nd gear using the universal bearing puller J-22912-01.

Fig 10: Removing Second Gear
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Remove the 2nd-gear needle bearing.

Fig 11: Removing Second-Gear Needle Bearing
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Remove the ring and the thrust washer.

Fig 12: Removing Thrust Washer And Ring
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Remove the 3rd gear and the synchronizer blocking ring.

Fig 13: Removing 3rd Gear And Synchronizer Blocking Ring
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Separate the synchronizer blocking ring from the 3rd gear.

Fig 14: Separating Synchronizer Blocking Ring From 3rd Gear
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Remove the 3rd-gear needle bearing from the mainshaft.

Fig 15: Identifying Third-Gear Needle Bearing
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Remove the synchronizer sleeve containing the keys and the spring.

Fig 16: Identifying Synchronizer Sleeve Containing Keys And Spring
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Remove the snap ring and the washer from the mainshaft.

Fig 17: Removing Snap Ring And Washer From Mainshaft
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Remove the 3rd - 4th synchronizer gear containing the synchronizer spring.

Fig 18: Identifying Third-Fourth Synchronizer Gear Containing Synchronizer Spring
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Remove the 4th-gear assembly.

Fig 19: Identifying Fourth-Gear Assembly
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Separate the synchronizer blocking ring from the 4th gear.

Fig 20: Separating Synchronizer Blocking Ring From 4th Gear
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Remove the 4th-gear needle bearing, the ring, and the thrust washer.

Fig 21: Removing 4th-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.