Countershaft Disassembly and Reassembly: Reassembly

Clean all components thoroughly, inspect them for any abnormality and replace with new one as necessary.
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

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

Service limit: 0.5 mm (0.020 in.)

Key slot width "b"

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

Limit: 10.45 mm (0.411 in.)

Fig 1: Identifying Clearance Between Synchronizer 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 (2nd)

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

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

Fig 2: Identifying Synchronizer Outer Ring, Inner Ring And Cone
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: Applying Air Into Countershaft 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 larger than those of high speed one.
Synchronizer key installation position

A = B

Fig 4: Identifying Low Speed Synchronizer Sleeve, Hub, Keys And Springs
Courtesy of SUZUKI OF AMERICA CORP.
Install right bearing cone (1) to counter shaft (2) by using special tools and hydraulic press.
Special Tool
1. 09913-76010
2. 09924-07720
  
  Fig 5: Identifying Right Bearing Cone And Counter Shaft
  Courtesy of SUZUKI OF AMERICA CORP.
Install needle bearing (4), apply oil to it, then install 1st gear and 1st gear synchronizer ring (2).
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 are aligned with keys (5) 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. 09913-85210
3. 09940-54910
4. 09924-07710
  
  Fig 6: Identifying Needle Bearing And 1st Gear Synchronizer Ring
  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 needle bearing.

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

Fig 7: Identifying Synchronizer Outer Ring, Center Cone And Inner Ring
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit 3rd gear (2) and spacer (1) by using special tools 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. 09913-85210
  
  Fig 8: Identifying 3rd Gear And Spacer
  Courtesy of SUZUKI OF AMERICA CORP.
Press-fit 4th gear (2) by using the same procedure at step 10).
Install left bearing cone (1) by using special tool and hydraulic press.
NOTE: For protection of bearing cone (3), always support shaft with special tool as shown in figure.

Special Tool

(A): 09923-78210

(E): 09913-80113

Fig 9: Identifying Bearing Cone And 4th Gear
Courtesy of SUZUKI OF AMERICA CORP.