Input Shaft Inspection

Reference: INPUT SHAFT DISASSEMBLY 

• 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 (Input shaft) (3rd and 4th) 

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

  Service limit: 0.5 mm (0.020 in.) 

  Key slot width "b" (3rd and 4th synchronizer ring) 

  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.
• Measure width of high speed gear shift fork end "a" and groove width of high speed synchronizer sleeve "b", 5th & reverse gear shift fork end "a" and groove width of 5th speed synchronizer sleeve "b" and then calculate clearance "c" as follows:

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

  If clearance exceeds limit, replace gear shift fork and sleeve.

  Clearance "c" between fork and sleeve for high speed and 5th speed 

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

  Limit: 1.0 mm (0.039 in.) 

  Fig 2: Identifying Clearance Between Fork And Sleeve For High Speed And 5th Speed

  Courtesy of SUZUKI OF AMERICA CORP.
• Check diameter of input shaft (1) and needle bush (2) as shown in figure. If measured value is out of specification, replace input shaft and/or bush.
  INPUT SHAFT AND NEEDLE BUSH SPECIFICATIONS (DIAMETER)
  
  

  Measuring portion	Standard
  "a"	30.002 - 30.015 mm (1.1812 - 1.1816 in.)
  "b"	34.975 - 34.991 mm (1.3770 - 1.3775 in.)
  "c"	30.959 - 30.975 mm (1.2189 - 1.2194 in.)
  "d"	27.987 - 28.000 mm (1.1019 - 1.1023 in.)
  "e"	27.967 - 27.980 mm (1.1011 - 1.1015 in.)
  "f"	19.980 - 19.993 mm (0.7867 - 0.7871 in.)
  "g"	28.000 - 28.013 mm (1.1024 - 1.1028 in.)
  "h"	34.975 - 34.991 mm (1.3770 - 1.3775 in.)

  Fig 3: Identifying Input Shaft And Needle Bush Dimensions

  Courtesy of SUZUKI OF AMERICA CORP.
• Using "V" blocks (1) and dial gauge (2), check runout.

  If runout exceeds limit below, replace input shaft (3).

  Input shaft runout 

  Limit: 0.02 mm (0.0008 in.) 

  Fig 4: Checking Input Shaft Runout Using Dial Gauge And V Block

  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 (standard) of gear 

  3rd and 4th gear: 40.000 - 40.025 mm (1.5748 - 1.5757 in.) 

  Fig 5: Check Inside Diameter Of Gear Using Cylinder Gauge

  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 spline portions and replace parts if excessive wear is found.