Synchronizer Ring

Check clearance "a" between synchronizer ring (1) and gear (2) while lightly pushing synchronizer ring by hand, and also check chamfered tooth of synchronizer outer ring. Replace with new one if necessary.
Clearance "a" between synchronizer ring and gear (4th, 5th, 6th and reverse)

Standard: 1.0 - 1.5 mm (0.040 - 0.055 in.)

Limit: 0.7 mm (0.020 in.)

Fig 1: Checking Clearance Between Synchronizer Ring And Gear (4th, 5th, 6th And Reverse)
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 synchronizer ring and replace with new one, if necessary.
Difference between synchronizer outer ring and inner ring (3rd)

Standard "b": 0.95 - 1.25 mm (0.038 - 0.049 in.)

Limit "b": 0.48 mm (0.019 in.)

Fig 2: Checking Difference Between Synchronizer Outer Ring And Inner Ring (3rd)
Courtesy of SUZUKI OF AMERICA CORP.
Check clearance "a" between synchronizer inner ring (2) and gear (1) as well as clearance "b" between synchronizer outer ring (4) and gear (1) respectively.
If measured value "a" or "b", whichever is smaller, is out of specifications replace new synchronizer inner ring (2), synchronizer center cone (3), synchronizer outer ring (4) and/or gear. And also check each chamfered tooth of synchronizer ring and replace with new one, if necessary.

Clearance "a" between synchronizer inner ring and gear, or clearance "b" between synchronizer outer ring and gear, whichever is smaller (1st and 2nd)

Standard: 0.75 - 1.65 mm (0.030 - 0.064 in.)

Limit: 0.38 mm (0.015 in.)

Fig 3: Checking Clearance Between Synchronizer Inner Ring And Gear
Courtesy of SUZUKI OF AMERICA CORP.