Input Shaft Disassembly and Reassembly: 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 hydraulic press.

Fig 1: Identifying Input Shaft Right Bearing And Input Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Drive out 5th gear spacer (2), left bearing (3) and 4th gear (4) all at once using puller (5) and hydraulic press.
CAUTION:
- To avoid gear tooth from being damaged, support it at flat side of bearing puller.
- 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: Identifying 5th Gear Spacer, Left Bearing And 4th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Take out 4th gear needle bearing and high speed synchronizer ring.
Using snap ring pliers (2), remove circlip (1).
NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.

Fig 3: Identifying Snap Ring Pliers And Circlip
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: To avoid gear tooth from being damaged, support it at flat side of bearing puller.

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