Input Shaft Disassembly and Reassembly: Reassembly

Reference: INPUT SHAFT INSPECTION 

Reference: GEAR SHIFT SHAFT AND FORK INSPECTION 

1. Install right bearing (1) to input shaft (2) using special tool and hydraulic press.

   Special Tool 

   1. 09941-74910 
   Fig 1: Installing Right Bering To Input Shaft Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
2. Fit high speed synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
   NOTE:

   • No specific direction is assigned to each key but it is assigned as sleeve & hub assembly.
   • Inside diameter at high speed synchronizer hub is larger than those of low speed synchronizer hub.
   Fig 2: Identifying Synchronizer Key Installation Position

   Courtesy of SUZUKI OF AMERICA CORP.
3. Install 3rd gear needle bearing and apply transaxle oil to it, and then install 3rd gear synchronizer inner ring (2), 3rd gear synchronizer center cone (3), 3rd gear synchronizer outer ring (4) and 3rd gear (1) to input shaft.
   NOTE: Make sure claws on 3rd gear synchronizer center cone fit into the holes on 3rd gear.
   Fig 3: Identifying 3rd Gear Synchronizer Center Cone, 3rd Gear Synchronizer Inner Ring And 3rd Gear Synchronizer Outer Ring

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install high speed sleeve & hub assembly (3) using special tool and hydraulic press and then install circlip.
   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 (1) after press-fitting sleeve & hub assembly.

   Special Tool 

   1. 09944-77030 
   Fig 4: Pressing High Speed Sleeve & Hub Assembly Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install 4th gear needle bearing (2) and apply transaxle oil to it, and then install synchronizer ring (4) and 4th gear (3).
6. Install 5th gear spacer (1) using special tools and hydraulic press.
   CAUTION: Use puller and hydraulic press that bears at least 5000 kgf (11023 lbf) safely.

   Special Tool 

   1. 09940-54910 
   2. 09913-85210 
   Fig 5: Installing 5th Gear Spacer Using Special Tools

   Courtesy of SUZUKI OF AMERICA CORP.
7. Install 5th gear needle bearing and apply transaxle oil to it, and then install 5th gear and synchronizer ring.
8. Fit 5th & 6th gear synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.
   NOTE:

   • No specific direction is assigned to 5th & 6th gear synchronizer hub or each key but it is assigned as assembly.
   • Inside diameter at 5th & 6th gear synchronizer hub is smaller than those of low speed synchronizer hub.
   Fig 6: Identifying Synchronizer Key Installation Position

   Courtesy of SUZUKI OF AMERICA CORP.
9. Install 5th & 6th gear synchronizer sleeve & hub assembly (1) using special tool and hydraulic press.

   Special Tool 

   1. 09913-85210 
   Fig 7: Installing 5th And 6th Gear Synchronizer Sleeve & Hub Assembly Using Special Tool

   Courtesy of SUZUKI OF AMERICA CORP.
10. Install 6th gear needle bearing (1) and apply transaxle oil to it, and then install synchronizer ring (3) and 6th gear (2).
11. Install 6th gear spacer (4) using special tool and hydraulic press.

    Special Tool 

    1. 09913-85210 
    Fig 8: Installing 6th Gear Spacer Using Special Tool

    Courtesy of SUZUKI OF AMERICA CORP.
12. Press-fit left bearing (1) using special tool and hydraulic press.

    Special Tool 

    1. 09913-85210 
    Fig 9: Pressing Left Bearing Using Special Tool

    Courtesy of SUZUKI OF AMERICA CORP.
13. Select circlip (1) that makes thrust clearance "a" of bearing 0.1 mm (0.004 in) or less and install it.
    Fig 10: Identifying Circlip Gap

    Courtesy of SUZUKI OF AMERICA CORP.

    Available circlip thickness 

    CIRCLIP THICKNESS SPECIFICATION
    
    

    Clearance "b"	Select circlip
    1.810 - 1.860 mm (0.0713 - 0.0732 in.)	1.81 mm (0.0713 in.)
    1.860 - 1.910 mm (0.0732 - 0.0751 in.)	1.86 mm (0.0732 in.)
    1.910 - 1.960 mm (0.0751 - 0.0771 in.)	1.91 mm (0.0751 in.)
    1.960 - 2.010 mm (0.0771 - 0.0791 in.)	1.96 mm (0.0771 in.)
    2.010 - 2.060 mm (0.0791 - 0.0811 in.)	2.01 mm (0.0791 in.)
    2.060 - 2.110 mm (0.0811 - 0.0831 in.)	2.06 mm (0.0811 in.)
    2.110 - 2.160 mm (0.0831 - 0.0850 in.)	2.11 mm (0.0831 in.)
    2.160 - 2.210 mm (0.0850 - 0.0870 in.)	2.16 mm (0.0850 in.)
    2.210 - 2.260 mm (0.0870 - 0.0889 in.)	2.21 mm (0.0870 in.)
    2.260 - 2.310 mm (0.0889 - 0.0909 in.)	2.26 mm (0.0889 in.)