Countershaft Disassembly and Assembly: Assembly

Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
If synchronizer parts need to be repaired, check clearance "a" between ring (2) and gear (1), each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Clearance "a" between synchronizer ring and gear

Standard: 1.0 - 1.4 mm (0.039 - 0.055 in.)

Service limit: 0.5 mm (0.019 in.)

Fig 1: Checking Clearance Between Ring And Gear
Courtesy of SUZUKI OF AMERICA CORP.
Put the synchronizer outer ring (1), inner ring (3) and the cone (2) together and then measure the step difference between the outer ring and the inner ring. And also check each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Difference between synchronizer outer ring and inner ring

Standard "b": 0.95 - 1.25 mm (0.036 - 0.048 in.)

Service limit "b": 0.5 mm (0.019 in.)

Fig 2: Measuring Step Difference Between Outer Ring And Inner Ring
Courtesy of SUZUKI OF AMERICA CORP.
To ensure lubrication of countershaft (1), air blow oil holes (2) and make sure that they are free from any obstruction.

Fig 3: Lubricating Countershaft Air Blow Oil Holes
Courtesy of SUZUKI OF AMERICA CORP.
Fit low speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure.
NOTE:
- No specific direction is assigned to each key but it is assigned as sleeve & hub assembly.
- Size of low speed synchronizer keys and springs are the largest compared with those of high speed and 5th speed ones.
Synchronizer key installation position

"A"="B"

Fig 4: Identifying Synchronizer Key Installation Position
Courtesy of SUZUKI OF AMERICA CORP.
Install right bearing cone (1) by using special tool and hammer.
Special Tool
1. 09923-78210
  
  Fig 5: Installing Right Bearing Cone By Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing, apply oil to it, then install 1st gear outer ring, center cone & inner ring put together.
Drive in low speed sleeve & hub assembly (1) by using special tools and hammer.
NOTE:
- Support shaft with special tool as shown in figure so that retainer of bearing cone (4) will be free from compression.
- Make sure that synchronizer ring key slots (2) are aligned with keys while press-fitting sleeve & hub assembly.
- Check free rotation of 1st gear (3) after press-fitting sleeve & hub assembly.
Special Tool
1. 09923-78210
2. 09940-51710
3. 09924-07730
4. 09924-07710
  
  Fig 6: Checking Free Rotation Of 1St Gear
  Courtesy of SUZUKI OF AMERICA CORP.
Install circlip (1) and confirm that circlip is installed in groove securely.
Install needle bearing (2) and apply oil to bearing.

With synchronizer outer ring (3), center cone (4) & inner ring (5) put together and installed to 2nd gear (6) as shown in figure.

Fig 7: Installing Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit 3rd gear (2) and spacer (1) by using special tool and hydraulic press.
NOTE: It is recommended to press-fit spacer and 3rd gear first, and then 4th gear later separately so that countershaft will not be compressed excessively.

Special Tool
1. 09923-78210
2. 09913-84510
  
  Fig 8: Installing 3rd Gear And Spacer By Using Special Tool
  Courtesy of SUZUKI OF AMERICA CORP.
Press-fit 4th gear (2) by using the same procedure.
Install left bearing cone (1) by using special tool and hammer.
NOTE: For protection of bearing cone (3), always support shaft with special tool as shown in figure.

Special Tool
1. (A): 09923-78210
2. (E): 09913-80113
  
  Fig 9: Installing Left Bearing Cone By Using Special Tool And Hammer
  Courtesy of SUZUKI OF AMERICA CORP.