Suzuki Baleno Manual page 482

7A-26 MANUAL TRANSMISSION (G13 AND G16 ENGINE MODELS)
1. Gear
2. Synchronizer ring
1. Countershaft
2. Oil hole
1. Low speed synchronizer spring
2. Key
3. Hub
4. Sleeve
1. R bearing cone
2. Countershaft
1. 1st gear synchronizer ring
2. 2nd gear synchronizer ring
Inspection and Reassembly
1) Clean all components thoroughly, inspect them for any ab-
normality and replace with new ones as necessary.
2) If synchronizer parts need to be repaired, check clearance "a"
between ring and gear, each chamfered tooth of gear, ring and
sleeve, then determine parts replacement.
Clearance "a": Standard 1.0 – 1.4 mm (0.039 – 0.055 in.)
3) To ensure lubrication, air blow oil holes and make sure that they
are free from any obstruction.
4) Fit high speed synchronizer sleeve to hub, insert 3 keys in it and
then set springs as illustrated left.
NOTE:
D No specific direction is assigned to low speed synchro-
nizer hub or each key but it is assigned as assembly.
D Size of low speed synchronizer keys and springs are the
largest compared with those of high speed and 5th
speed ones.
A = B
C: Key way
5) Install R bearing cone by using special tool and hammer.
Special Tool
(A): 09923-78210
6) Install needle bearing, apply oil to it, then install 1st gear and 1st
gear synchronizer ring.
NOTE:
D Key slot width of 1st synchronizer ring is smaller than
that of 2nd synchronizer ring.
Distinguish the difference properly.
Width "b": 8.2 mm (0.32 in.)
"c": 9.6 mm (0.38 in.)
D Needle bearings for 1st and 2nd gear are identical.
Service limit 0.5 mm (0.019 in.)