Suzuki RA410, Manual

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4) Fit low speed synchronizer sleeve (1) to hub (2), insert 3 keys
(3) in it and then set springs (4) as shown in left figure.
NOTE:
No specific direction is assigned to low speed synchro-
nizer hub or each key but it is assigned as assembly.
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
Clutch
side 4
3
3
2
1
3
5) Install needle bearing, apply oil to it, then install 1st gear and 1st
gear synchronizer ring (1).
NOTE:
Key slot width of 1st synchronizer ring is smaller than
that of 2nd synchronizer ring (2).
Distinguish the difference properly.
Width “b”: 8.2 mm (0.32 in.)
“c”: 8.8 mm (0.35 in.)
Needle bearings for 1st and 2nd gear are identical.
6) Drive in low speed sleeve & hub assembly (1) using special tool
and hammer.
NOTE:
Support shaft with special tool as illustrated left so that
retainer of bearing cone will be free from compression.
Make sure that synchronizer ring key slots are aligned
with keys while press-fitting sleeve & hub assembly.
Check free rotation of 1st gear after press-fitting sleeve
& hub assembly.
Special Tool
(A): 09913-85210
(B): 09940-53111
A: Align key slots with keys
A
7) Install circlip (1), needle bearing (2), apply oil to bearing, then
install 2nd gear synchronizer ring (3) and 2nd gear (4).
NOTE:
Confirm that circlip is installed in groove securely.
1
2 3
4
7A-22 MANUAL TRANSMISSION