Main Shaft Inspection

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.

Fig 1: Synchronizer Ring & Gear Clearance & Key Slot Width Specifications Chart
Courtesy of SUZUKI OF AMERICA CORP.

Fig 2: Checking Clearance "a" Between Synchronizer Ring & Gear & Key Slot Width "b"
Courtesy of SUZUKI OF AMERICA CORP.
Check clearance between fork and sleeve.
If clearance exceeds limit, replace fork and sleeve.

Clearance between fork and sleeve
1. Standard: 0.15 - 0.35 mm (0.006 - 0.014 in.)
2. Limit: 1.0 mm (0.039 in.)
Fig 3: Checking Clearance Between Fork & Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Check diameter of main shaft (1)/needle bush (2) and thickness of main shaft (1)/needle bush (2) flanges as shown in the figure. If measured value is out of specification, replace them (or it).

Fig 4: Main Shaft/Needle Bush Specifications (Diameter & Thickness) Chart
Courtesy of SUZUKI OF AMERICA CORP.

Fig 5: Checking Diameter Of Main Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Using "V" blocks (1) and dial gauge (2), check runout.
If runout exceeds limit below, replace main shaft (3).

Main shaft runout
1. Limit: 0.06 mm (0.0024 in.)
Fig 6: Checking Runout
Courtesy of SUZUKI OF AMERICA CORP.
Using cylinder gauge (1), check inside diameter of each gear. If its inside diameter exceeds specification, replace it.
Inside diameter of gear

1st, 2nd and 3rd
1. Standard: 44.015 - 44.040 mm (1.7329 - 1.7339 in.)
Fig 7: Checking Inside Diameter Of Gear
Courtesy of SUZUKI OF AMERICA CORP.
Check chamfered part of each sleeve for damage and excessive wear, and replace as necessary.
Check each synchronizer key and synchronizer spring and replace as necessary.
Check splined portions and replace parts if excessive wear is found.
Check 2nd gear (1) thrust clearance by using thickness gauge (2). If clearance is out of specification, repress-fit or replace defective part.
2nd gear thrust clearance
1. Standard: 0.10 - 0.25 mm (0.004 - 0.010 in.)
Fig 8: Checking 2nd Gear Thrust Clearance
Courtesy of SUZUKI OF AMERICA CORP.
Check low gear (1) thrust clearance by using thickness gauge (2).
If clearance is out of specification, repress-fit or replace main shaft bearing and 5th gear.

Low gear thrust clearance
1. Standard: 0.10 - 0.25 mm (0.004 - 0.010 in.)
Fig 9: Checking Low Gear Thrust Clearance
Courtesy of SUZUKI OF AMERICA CORP.