Countershaft And Reverse Idle Gear Inspection

Reference: COUNTERSHAFT DISASSEMBLY AND ASSEMBLY 

• Using micrometer, check diameter of countershaft (1) and needle bush (2) as shown. If measured value is out of specification, replace counter and/or bush.

  Countershaft diameter (standard) 

  COUNTERSHAFT DIAMETER SPECIFICATIONS
  
  

  Measuring portion	Standard
  "a"	25.002-25.015 mm (0.9843-0.9848 in.)
  "b"	27.987-28.000 mm (1.1019-1.1023 in.)
  "c"	27.987-28.000 mm (1.1019-1.1023 in.)
  "d"	30.959-30.975 mm (1.2189-1.2194 in.)
  "e"	34.975-34.991 mm (1.3770-1.3775 in.)
  "f"	25.002-25.015 mm (0.9843-0.9848 in.)
  "g"	28.000-28.013 mm (1.1023-1.1028 in.)
  "h"	34.975-34.991 mm (1.3770-1.3776 in.)

  Fig 1: Identifying Countershaft & Needle Bush Diameter

  Courtesy of SUZUKI OF AMERICA CORP.
• Measure width "a" of low speed gear shift fork and groove width "b" of low speed gear synchronizer sleeve and then calculate clearance "c" as follows:

  Clearance "c" = "b" - "a"

  If clearance exceeds limit, replace fork bush (1) and sleeve.

  Clearance "c" between fork and sleeve 

  Standard: 0.2-0.5 mm (0.008-0.020 in.) 

  Limit: 1.0 mm (0.039 in.) 

  Fig 2: Measuring Width Of Low Speed Gear Shift Fork & Groove Width

  Courtesy of SUZUKI OF AMERICA CORP.
• Check clearance "a" between synchronizer ring (2) and gear (1), 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.

  Clearance "a" between synchronizer ring and gear (Countershaft) (1st and 2nd) 

  Standard: 1.0-1.4 mm (0.040-0.055 in.) 

  Service limit: 0.5 mm (0.020 in.) 

  Key slot width "b" (1st and 2nd synchronizer ring) 

  Standard: 10.0-10.2 mm (0.394-0.401 in.) 

  Limit: 10.45 mm (0.411 in.) 

  Fig 3: Identifying Clearance Between Synchronizer Ring & Gear

  Courtesy of SUZUKI OF AMERICA CORP.
• Using cylinder gauge (1), check inside diameter of countershaft 1st and 2nd gears (2). If measured value exceeds specification, replace countershaft 5th gear.

  Countershaft 1st and 2nd gears diameter 

  Standard: 40.000-40.025 mm (1.5748-1.5757 in.) 

  Fig 4: Identifying Countershaft 1st & 2nd Gears Inside Diameter

  Courtesy of SUZUKI OF AMERICA CORP.
• Check oil clearance between reverse idle gear (2) and shaft (1) measuring inside diameter "a" of gear and diameter "b" of shaft and calculate as follows:

  Clearance "c" = "b" - "a"

  If clearance exceeds limit, replace gear and shaft.

  Oil clearance "c" between reverse idle gear and shaft 

  Standard: 0.016-0.045 mm (0.0006-0.0018 in.) 

  Limit: 0.13 mm (0.005 in.) 

  Fig 5: Identifying Oil Clearance Between Reverse Idle Gear & Shaft

  Courtesy of SUZUKI OF AMERICA CORP.
• Check clearance between reverse idle gear (2) and lever (1) of reverse gear shift link. If clearance exceeds limit, replace gear and lever.

  Clearance between reverse idle gear and lever 

  Standard: 0.05 mm-0.25 mm (0.002-0.010 in.) 

  Limit: 0.5 mm (0.020 in.) 

  Fig 6: Identifying Clearance Between Reverse Idle Gear & Lever

  Courtesy of SUZUKI OF AMERICA CORP.