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Main Shaft Assembly

Reference: MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING 

Reference: MANUAL TRANSMISSION UNIT DISASSEMBLY 

Reference: MAIN SHAFT DISASSEMBLY 

Reference: MAIN SHAFT INSPECTION 

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.
  1. Assembly high speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
    1. Install synchronizer springs (1) and synchronizer keys (2) to high speed synchronizer hub (3) as shown in the figure.
    2. Slide hub (3) in sleeve (4) so that chamfered side of sleeve (4) and small diameter boss side of hub (3) face opposite as shown in the figure, also aligning hub slots with key location teeth of sleeve (4).
      Fig 1: Identifying Synchronizer Springs, Synchronizer Keys, High Speed Synchronizer Hub & Sleeve
      G04723063Courtesy of SUZUKI OF AMERICA CORP.
  2. Assembly 3rd gear (1), synchronizer inner ring (2), synchronizer cone ring (4) and synchronizer outer ring according to the following procedure.
    1. Install the synchronizer inner ring (2) to 3rd gear (1).
    2. Install synchronizer cone ring (4) to 3rd gear (1).
      NOTE: Fit protrusion (5) of synchronizer cone ring (4) into groove (3) of 3rd gear.
      Fig 2: Identifying Synchronizer Cone Ring, 3rd Gear, Synchronizer Inner Ring, Synchronizer Cone Ring, Groove & Protrusion
      G04723064Courtesy of SUZUKI OF AMERICA CORP.
    3. Install synchronizer outer ring (1) to 3rd gear (2).
      Fig 3: Identifying Synchronizer Outer Ring & 3rd Gear
      G04723065Courtesy of SUZUKI OF AMERICA CORP.
    4. Align protrusion (1) of synchronizer outer ring into slot (2) of synchronizer hub, and then attach high speed synchronizer sleeve and hub assembly to 3rd gear (3). Also align protrusion (4) of synchronizer inner ring and dent (5) of high speed synchronizer hub.
      Fig 4: Identifying Protrusion Of Synchronizer Outer Ring, Slot Of Synchronizer Hub, 3rd Gear, Protrusion Of Synchronizer Inner Ring & Dent Of High Speed Synchronizer Hub
      G04723066Courtesy of SUZUKI OF AMERICA CORP.
  3. Install needle bearing (2) to main shaft (1) and press fit 3rd gear high speed synchronizer sleeve and hub assembly (3), which was assembled in step  a through  d, to main shaft (1) using special tool and hydraulic press.

    Special Tool 

    (A): 09940-53111 

    Fig 5: Identifying Needle Bearing, Main Shaft, Hub Assembly & Special Tool
    G04723067Courtesy of SUZUKI OF AMERICA CORP.
  4. Select circlip (1) that will make thrust clearance of high speed synchronizer hub 0.1 mm (0.0039 in) or less and install it.
    CIRCLIP THICKNESS SPECIFICATIONS

    ID mark Circlip thickness ID mark Circlip thickness
    A 1.80 - 1.85 mm (0.0709 - 0.0728 in.) E 2.00 - 2.05 mm (0.0789 - 0.0807 in.)
    B 1.85 - 1.90 mm (0.0728 - 0.0748 in.) F 2.05 - 2.10 mm (0.0807 - 0.0827 in.)
    C 1.90 - 1.95 mm (0.0748 - 0.0768 in.) G 2.10 - 2.15 mm (0.0826 - 0.0846 in.)
    D 1.95 - 2.00 mm (0.0768 - 0.0787 in.)    

    Special Tool 

    (B): 09900-06107 

    Fig 6: Identifying Circlip & Special Tool
    G04723068Courtesy of SUZUKI OF AMERICA CORP.
  5. After installing circlip, check that 3rd gear turns lightly.
  6. Check 3rd gear (2) thrust clearance 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 7: Identifying 3rd Gear & Thickness Gauge
    G04723069Courtesy of SUZUKI OF AMERICA CORP.
  7. Assemble low speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
    1. Install synchronizer springs (1) and synchronizer keys (2) to low speed synchronizer hub (3) as shown in the figure.
    2. Slide low speed synchronizer hub (3) in sleeve (4) so that flange side of sleeve (4) and small diameter boss side of hub (3) face opposite as shown the figure, also aligning hub slots with key location teeth of sleeve (4).
      Fig 8: Identifying Low Speed Synchronizer Hub, Sleeve, Springs And Keys
      G04723070Courtesy of SUZUKI OF AMERICA CORP.
  8. Assemble 2nd gear (1), synchronizer inner ring (2), synchronizer cone ring (3) and synchronizer outer ring according to the following procedure.
    1. Install synchronizer inner ring (2) to 2nd gear (1).
    2. Install synchronizer cone ring (4) to 2nd gear (1).
      NOTE: Fit protrusion (4) of synchronizer cone ring (4) into groove (3) of 2nd gear.
      Fig 9: Identifying Synchronizer Cone Ring, 2nd Gear, Groove & Protrusion
      G04723071Courtesy of SUZUKI OF AMERICA CORP.
    3. Install synchronizer outer ring (1) to 2nd gear (2).
      Fig 10: Identifying Synchronizer Outer Ring & 2nd Gear
      G04723072Courtesy of SUZUKI OF AMERICA CORP.
    4. Install 2nd gear (3), fitting slot (1) of low speed synchronizer hub in protrusion (2) of synchronizer outer ring as shown in the figure. Also align protrusion (4) of synchronizer inner ring and dent (5) of low speed synchronizer hub.
      Fig 11: Identifying 2nd Gear, Slot Of Low Speed Synchronizer Hub, Protrusions & Dent
      G04723073Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the needle bearing to the 2nd gear, then as the figure shows press fit 2nd gear low speed synchronizer sleeve and hub assembly (1), which was assembled in step  a through  d, into main shaft (2) using special tool. Press-fit low speed sleeve and hub assembly with special tool and hydraulic press (3).

    Special Tool 

    (A): 09944-78210 

    Fig 12: Identifying 2nd Gear Low Speed Synchronizer Sleeve And Hub Assembly, Main Shaft & Hydraulic Press
    G04723074Courtesy of SUZUKI OF AMERICA CORP.
  10. Select circlip (1) that will make thrust clearance of low speed synchronizer hub 0.1 mm (0.0039 in.) or less and install it.
    CIRCLIP THICKNESS SPECIFICATIONS

    ID mark Circlip thickness ID mark Circlip thickness
    A 2.30 - 2.35 mm (0.0906 - 0.0925 in.) E 2.50 - 2.55 mm (0.0984 - 0.1004 in.)
    B 2.35 - 2.40 mm (0.0925 - 0.0945 in.) F 2.55 - 2.60 mm (0.1004 - 0.1024 in.)
    C 2.40 - 2.45 mm (0.0945 - 0.0965 in.) G 2.60 - 2.65 mm (0.1024 - 0.10433 in.)
    D 2.45 - 2.50 mm (0.0965 - 0.0984 in.)    

    Special Tool 

    (A): 09900-06107 

    Fig 13: Identifying Circlip & Special Tool
    G04723075Courtesy of SUZUKI OF AMERICA CORP.
  11. Check 2nd gear thrust clearance, referring to MAIN SHAFT ASSEMBLY .
  12. Install spacer (1) and needle bearing (2) to main shaft (3).
    Fig 14: Identifying Spacer, Needle Bearing & Main Shaft
    G04723076Courtesy of SUZUKI OF AMERICA CORP.
  13. Install synchronizer outer ring (1) to low speed synchronizer hub (2).
    NOTE: Fit protrusion (3) of synchronizer outer ring (1) into groove (4) of low speed synchronizer hub (2).
    Fig 15: Identifying Synchronizer Outer Ring, Low Speed Synchronizer Hub, Protrusion & Groove
    G04723077Courtesy of SUZUKI OF AMERICA CORP.
  14. Install synchronizer cone ring (1) and synchronizer inner ring (2).
    NOTE: Fit protrusion (3) of synchronizer inner ring (2) into dent (4) of low speed synchronizer hub (5).
    Fig 16: Identifying Synchronizer Cone Ring, Synchronizer Inner Ring, Protrusion, Dent & Low Speed Synchronizer Hub
    G04723078Courtesy of SUZUKI OF AMERICA CORP.
  15. Install low gear (1) to main shaft (2).
    NOTE:
    • Fit protrusion (3) of synchronizer cone ring (5) into groove (4) of low gear (1).
    • After installation, check synchronizer outer ring (5) moves in circumferential direction.
      Fig 17: Identifying Low Gear, Main Shaft, Protrusion, Synchronizer Cone Ring, Groove & Synchronizer Outer Ring
      G04723079Courtesy of SUZUKI OF AMERICA CORP.
  16. Install pin (1) and low gear thrust washer (2) to main shaft.
    NOTE: Check the cut in low gear thrust washer and pin are engaged.
    Fig 18: Identifying Pin And Low Gear Thrust Washer
    G04723080Courtesy of SUZUKI OF AMERICA CORP.
  17. Press-fit main shaft bearing (1) and 5th gear (3) with special tool and hydraulic press (2).
    NOTE:
    • Bring bearing so that its groove for circlip is in the rear.
    • Bring 5th gear (3) so that its small diameter boss "a" is in the rear.

    Special Tool 

    (C): 09940-51710 

    Fig 19: Identifying Main Shaft Bearing, 5th Gear, Hydraulic Press & Special Tool
    G04723081Courtesy of SUZUKI OF AMERICA CORP.
  18. 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
    C 2.75 - 2.80 mm (0.1083 - 0.1102 in.) J 3.05 - 3.10 mm (0.1201 - 0.1220 in.)
    D 2.80 - 2.85 mm (0.1102 - 0.1122 in.) K 3.10 - 3.15 mm (0.1220 - 0.1240 in.)
    E 2.85 - 2.90 mm (0.1122 - 0.1142 in.) L 3.15 - 3.20 mm (0.1240 - 0.1260 in.)
    F 2.90 - 2.95 mm (0.1142 - 0.1161 in.) M 3.20 - 3.25 mm (0.1260 - 0.1280 in.)
    G 2.95 - 3.00 mm (0.1161 - 0.1181 in.) N 3.25 - 3.30 mm (0.1280 - 0.1299 in.)
    H 3.00 - 3.05 mm (0.1181 - 0.1201 in.) P 3.30 - 3.35 mm (0.1299 - 0.1319 in.)
    Fig 20: Identifying Circlip & Thickness Gauge
    G04723082Courtesy of SUZUKI OF AMERICA CORP.
  19. Check low gear clearance referring to MAIN SHAFT ASSEMBLY .
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