Input Shaft Reassembly

Reference: INPUT SHAFT DISASSEMBLY 

Reference: INPUT SHAFT INSPECTION 

1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.
   Fig 1: Checking Oil Holes

   Courtesy of SUZUKI OF AMERICA CORP.
3. Install snap ring (2) in specified direction as shown in figure and then drive in input shaft front bearing (1) to input shaft using special tool and hammer.

   Special Tool 

   (A): 09940-51710 

   Fig 2: Identifying Snap Ring Position

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4. Apply oil to high speed gear needle bearing (6), and then install needle bearing, 4th gear (5) and high speed synchronizer ring (7) to input shaft.
5. Assemble synchronizer sleeve (4) and hub (3) as follows.
   1. Fit high speed synchronizer sleeve to hub in specified direction as shown in figure.
   2. Insert 3 keys (2) to hub.
   3. Set springs (1) at specified position as shown in figure.

      Synchronizer key installation position 

      : A = B 

      Fig 3: Identifying Synchronizer Key Installation Position

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6. Drive in high speed synchronizer assembly (1) using special tool and hydraulic press.
   NOTE:

   • While press-fitting sleeve & hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly.
   • Check free rotation of 4th gear after press fitting sleeve & hub assembly.

   Special Tool 

   (A): 09913-84510 

   Fig 4: Installing High Speed Synchronizer Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
7. Check 4th gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

   4th gear thrust clearance 

   "a": 0.10 - 0.30 mm (0.004 - 0.012 in.) 

   Fig 5: Identifying 4th Gear Thrust Clearance

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8. Apply oil to high speed gear needle bearing, and then install 3rd gear bush (1), high speed gear needle bearing (2) and 3rd gear (3).
   Fig 6: Identifying 3rd Gear Bush, High Speed Gear Needle Bearing And 3rd Gear

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9. Press-fit 5th speed synchronizer hub (1) using special tool and hydraulic press.

   Special Tool 

   (A): 09913-84510 

   Fig 7: Installing 5th Speed Synchronizer Hub

   Courtesy of SUZUKI OF AMERICA CORP.
10. Check 3rd gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

    3rd gear thrust clearance 

    "a": 0.10 - 0.30 mm (0.004 - 0.012 in.) 

    Fig 8: Identifying 3rd Gear Thrust Clearance

    Courtesy of SUZUKI OF AMERICA CORP.
11. Tighten input shaft 5th hub nut to specified torque in the same manner as Step 3) of INPUT SHAFT DISASSEMBLY .
    CAUTION: Do not hold spline, gear teeth or abrasived surface of shaft with vise through "V" blocks or the like, otherwise shaft components may be damaged.

    Tightening torque 

    Input shaft 5th hub nut: 210 N.m (21.0 kg-m, 152.0 lbf-ft) 

12. Caulk input shaft 5th hub nut (2) using caulking tool.