Countershaft & Main Shaft Inner Parts Inspection

Check for the following items.

• Check tooth surface of gear and rotation of bearing and replace with new one if necessary. As long as no abnormal condition such as noise exists before removal, replacement is unnecessary.
  Fig 1: Checking Bearing Rotation

  Courtesy of SUZUKI OF AMERICA CORP.
• Inspect needle bearings and needle contacting surfaces (rotating surfaces) and replace with new ones as required.
  NOTE: Should abnormal noise be heard before disassembly, it is necessary to carefully check needle contacting surface inside of each gear besides those parts shown in the figure.
  Fig 2: Identifying Main Shaft, Needle Bearings & Needle Bearing Bushings

  Courtesy of SUZUKI OF AMERICA CORP.
• Check clearance "a" between synchronizer ring and gear, 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 

  1. Standard:  1.0 - 1.4 mm (0.039 - 0.055 in.)
  2. Limit:  0.5 mm (0.020 in.)
  1. Key slot width "b" 
  2. Standard:  10.1 mm (0.398 in.)
  3. Limit:  10.4 mm (0.409 in.)
  Fig 3: Identifying Gear & Synchronizer Ring Clearances

  Courtesy of SUZUKI OF AMERICA CORP.
• Check chamfered part of each sleeve for damage and excessive wear, and replace as necessary.
• Using feeler gauge, check clearance "c" between sleeve (1) and shifter fork (2) and replace parts if necessary.

  Clearance "c" between sleeve and shifter fork 

  Maximum:  1.0 mm (0.039 in.)

  Fig 4: Identifying Clearance Between Sleeve & Shifter Fork

  Courtesy of SUZUKI OF AMERICA CORP.
• Check each synchronizer key and synchronizer spring and replace as necessary.
• Check splined portions and replace parts if excessive wear are found.