Input Shaft Disassembly and Assembly: Disassembly

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

Remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and press.

Fig 1: Removing Input Shaft Right Bearing From Input Shaft Using Bearing Puller
Courtesy of SUZUKI OF AMERICA CORP.
Drive out 5th gear spacer (2) and left bearing (3) all at once using puller (4) and hydraulic press.
CAUTION: Stop press work in the middle way and take out 5th gear bush to prevent it from being compressed and then continue to remove bearing with gear.

Fig 2: Removing 5th Gear Spacer And Left Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Take out 4th gear, 4th gear needle bearing and high speed synchronizer ring.
Using special tool, remove circlip (1).
NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.

Special Tool
1. 09900-06107
  
  Fig 3: Identifying Synchronizer Gear Clearance
  Courtesy of SUZUKI OF AMERICA CORP.
Drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) by using puller (4) and hydraulic press.
CAUTION: Make sure to use flat side of puller to avoid causing damage to 3rd gear tooth.

Fig 4: Removing High Speed Synchronizer Sleeve Hub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Take out 3rd gear needle bearing from shaft.
Disassemble synchronizer sleeve & hub assembly.