Input Shaft Disassembly and Reassembly: Reassembly

Reference: INPUT SHAFT INSPECTION 

Reference: GEAR SHIFT SHAFT AND FORK INSPECTION 

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

   Special Tool 

   1. 09941-74910 
      Fig 1: Identifying Right Bering

      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.
   • Size of high speed synchronizer sleeve and hub are the smaller than those of low speed one.
     Fig 2: Synchronizer Key Installation Position

     Courtesy of SUZUKI OF AMERICA CORP.
3. Install 3rd gear needle bearing (4), apply oil to it, then install 3rd gear (1) and synchronizer ring (2).
4. Drive in 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 after press-fitting sleeve & hub assembly.

   Special Tool 

   1. 09944-77030 
      Fig 3: Identifying Gear Needle Bearing

      Courtesy of SUZUKI OF AMERICA CORP.
5. Install 4th gear needle bearing (2), apply oil to it, then install 4th gear (3) and synchronizer ring (4).
6. Drive in 5th gear spacer (1) using special tool and hydraulic press.
   CAUTION: Using an inappropriate hydraulic press or bearing puller could cause personal injury. Make sure that both the hydraulic press and bearing puller are capable of safely bearing a load of at least 5 tons (11,000 lbs).

   Special Tool 

   1. 09940-54910 
   2. 09913-85210 
      Fig 4: Identifying Special Tool And Hydraulic Press

      Courtesy of SUZUKI OF AMERICA CORP.
7. Install 5th gear needle bearing, apply oil to it, 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.
   • Size of 5th & 6th gear synchronizer sleeve and hub are the smaller than those of high speed one.
     Fig 5: Synchronizer Key Installation Position

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

   Special Tool 

   1. 09913-85210 
      Fig 6: Identifying Gear Synchronizer Sleeve And Hub Assembly

      Courtesy of SUZUKI OF AMERICA CORP.
10. Install 6th gear needle bearing (1), apply oil to it, then install 6th gear (2) and synchronizer ring (3).
11. Using same special tool at step , drive in 6th gear spacer (4).
    Fig 7: Installing 6th Gear Needle Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
12. Using same special tool at step , press-fit left bearing (1).
    Fig 8: Pressing Left Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
13. Select circlip (1) that will make thrust clearance "a" of bearing 0.1 mm (0.004 in) or less and install it.
    Fig 9: Identifying Circlip Clearance

    Courtesy of SUZUKI OF AMERICA CORP.

    Available circlip thickness 

    CIRCLIP THICKNESS SPECIFICATIONS
    
    

    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.)