Input Shaft Disassembly and Reassembly: Reassembly

Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
Check clearance "a" between synchronizer ring (2) and gear (1), key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Clearance "a" between synchronizer ring and gear

Standard: 1.0 - 1.4 mm (0.040 - 0.055 in.)

Service limit: 0.5 mm (0.020 in.)

Key slot width "b"

Standard: 10.0 - 10.2 mm (0.394 - 0.401 in.)

Limit: 10.45 mm (0.411 in.)

Fig 1: Checking Clearance Between Synchronizer Ring And Gear
Courtesy of SUZUKI OF AMERICA CORP.
To ensure lubrication of input shaft (1), air blow oil holes (2) and make sure that they are free from any obstruction.

Fig 2: Applying Air Into Oil Holes Of Input Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure.
NOTE:
- No specific direction is assigned to high speed synchronizer sleeve or each key but it is assigned as assembly.
- Size of high speed synchronizer sleeve, hub, keys and springs are the smaller than those of low speed one.
Synchronizer key installation position

A = B

Fig 3: Identifying High Speed Synchronizer Sleeve, Hub, Keys And Springs
Courtesy of SUZUKI OF AMERICA CORP.
Drive in right bearing (1) to input shaft (2) using special tool and hydraulic press.
Special Tool

(A): 09913-80113

Fig 4: Identifying Right Bering And Input Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install 3rd gear needle bearing (4), apply oil to it, then install 3rd gear (1) and synchronizer ring (2).
Drive in high speed sleeve & hub assembly (3) by using special tool and hydraulic press.
NOTE:
- While press-fitting sleeve & hub, make sure that synchronizer ring key slots are aligned with keys (5) in sleeve & hub assembly.
- Check free rotation of 3rd gear after press-fitting sleeve & hub assembly.
- Synchronizer rings for 3rd and 4th are identical.
Special Tool

(B): 09913-84510

Fig 5: Identifying 3rd Gear Needle Bearing, 3rd Gear And Synchronizer Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install circlip (1) and confirm that circlip is installed in groove securely. Install needle bearing (2) of apply oil to it and then install synchronizer ring (3) and 4th gear (4).

Fig 6: Identifying Circlip, Needle Bearing, Synchronizer Ring And 4th Gear
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit left bearing (2) by using special tool and hydraulic press.
Special Tool

(A): 09913-80113
Using the same special tool at step 9), drive in 5th gear spacer (1).
CAUTION: To prevent 5th gear spacer (1) from being distorted because of excessive compression, do not press fit it with left bearing (2) at once.

Fig 7: Identifying 5th Gear Spacer And Bearing
Courtesy of SUZUKI OF AMERICA CORP.