Input Shaft Inspection

Reference: INPUT SHAFT DISASSEMBLY AND ASSEMBLY 

• 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: Identifying Clearance Between Synchronizer Ring And Gear, Width Of Index Protrusion & Key Slot Width

  Courtesy of SUZUKI OF AMERICA CORP.