Input Shaft Inspection

• Check clearance "a" between synchronizer ring and gear, width of index protrusion "b" in synchronizer ring, key slot width "c" in high speed synchronizer hub 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 (input shaft) 

Standard:  0.7 - 1.7 mm (0.028 - 0.067 in.)

Service limit:  0.5 mm (0.020 in.)

Width of index protrusion "b" (input shaft) 

Standard:  3.9 - 4.1 mm (0.154 - 0.161 in.)

Service limit:  3.6 mm (0.142 in.)

Key slot width "c" (high speed synchronizer hub) 

Standard:  8.0 - 8.1 mm (0.315 - 0.319 in.)

Fig 1: Checking Clearance Between Synchronizer Ring & Gear

Courtesy of SUZUKI OF AMERICA CORP.