Main Shaft Disassembly

Reference: MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING 

Reference: MANUAL TRANSMISSION UNIT DISASSEMBLY 

1. Remove circlip (1) from main shaft (2) using flat head screwdrivers or the like.
   Fig 1: Identifying Circlip & Main Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
2. 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: Identifying 5th Gear, Main Shaft Bearing, Low Gear Thrust Washer, Low Gear, Bearing Puller & Hydraulic Press

   Courtesy of SUZUKI OF AMERICA CORP.
3. 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: Identifying Low Gear Synchronizer Inner Ring, Synchronizer Cone Ring, Synchronizer Outer Ring, Pin, Needle Bearing And Spacer

   Courtesy of SUZUKI OF AMERICA CORP.
4. 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: Identifying Circlip, 2nd Gear, Needle Bearing, 2nd Gear Synchronizer Outer Ring, Cone Ring, Inner Ring, Sleeve/Hub Assembly, Puller & Hydraulic Press

   Courtesy of SUZUKI OF AMERICA CORP.
5. 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: Identifying Circlip, 3rd Gear, Needle Bearing, 3rd Gear Synchronizer Outer Ring, Cone Ring, Inner Ring, High Speed Synchronizer Sleeve/Hub Assembly, Puller & Hydraulic Press

   Courtesy of SUZUKI OF AMERICA CORP.
6. Remove high speed synchronizer sleeve from high speed synchronizer hub (2).
7. 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: Identifying Keys, High Speed Synchronizer Hub & Flat Head Screwdriver

   Courtesy of SUZUKI OF AMERICA CORP.
8. Remove low speed synchronizer sleeve/hub in similar manner as steps  6 and  7.