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.

SYNCHRONIZER RING AND GEAR CLEARANCE AND KEY SLOT WIDTH SPECIFICATIONS

Measuring point		Standard	Limit
"a"		1.0-2.0 mm (0.039 - 0.079 in.)	0.8 mm (0.031 in.)
"b"	1st and 2nd	12.2-12.4 mm (0.480 - 0.488 in.)	12.65 mm (0.498 in.)
"b"	3rd	10.0-10.2 mm (0.394 - 0.402 in.)	10.45 mm (0.411 in.)

Fig 1: Inspecting Main Shaft

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

Standard: 0.15 - 0.35 mm (0.006 - 0.014 in.)

Limit: 1.0 mm (0.039 in.)

Fig 2: Checking Clearance Between Fork And 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).

MAIN SHAFT / NEEDLE BUSH SPECIFICATIONS (DIAMETER AND THICKNESS)

Measuring portion	Standard
A	37.984 - 38.000 mm (1.4954-1.4960 in.)
B	34.984 - 35.000 mm (1.3773-1.3780 in.)
C	4.800 - 5.200 mm (0.1890 - 0.2047 in.)
D	38.985 - 39.000 mm (1.5348-1.5354 in.)
E	3.955-4.195 mm (0.1557-0.1652 in.)

Fig 3: Checking Diameter Of Main Shaft / Needle Bush And Thickness 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

Limit: 0.06 mm (0.0024 in.)

Fig 4: Measuring Main Shaft 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 Standard: 44.015 - 44.040 mm (1.7329 - 1.7339 in.)

Fig 5: 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

Standard: 0.10 - 0.25 mm (0.004 - 0.010 in.)

Fig 6: Inspecting 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

Standard: 0.10 - 0.25 mm (0.004 - 0.010 in.)

Fig 7: Measuring Low Gear Thrust Clearance

Courtesy of SUZUKI OF AMERICA CORP.