[Bear95]

I tried to set everything up by the book

RMIII
1996 Suzuki X-90 2wd manual 16valve 1.6l

Which book are you using? Do you have a FSM? Are you the original owner? Generally, unless the clutch pedal splines slip/strip or someone has been messing around with the factory settings, no need for under dash adjustment is required. Being a 96 you should not have splines on the pedal arm but a square end that is harder to damage.
You did not mention if your bulkhead is OK.
As Bex said you need the correct cable as it is usually the cause of clutch problems. There have been posts on here where previouly owner install the wrong cable and new owners are at a disadvantage to begin with.
B95

 

[Bear95]

I cannot get it into first until I'm just about stopped and when shifting either up or down into second gear it slightly grinds.


RMIII
1996 Suzuki X-90 2wd manual 16valve 1.6l

1st gear doesn't have synchronizers so you have to be stopped before shifting into it.

Have you done a spin down test of the clutch?

From FSM, clutch section page 7C-3 Clutch "Spin Down" Time.
1. Run engine at normal idle with the transmission in neutral and clutch engaged.
2. Disengage the clutch (clutch pedal depressed), wait approximately nine seconds and shift into reverse.
3. If grinding noise is heard, check the clutch for engagement.

After performing the preliminary checks and checking clutch spin down time, refer to (fiqure2) "Clutch Diagnosis" to assist in proper diagnosis of clutch problems.



B95

 

[Bear95]

First gear used to be synchronize before I had it rebuilt, and sometimes it goes in while moving with no problem. It never grinds into first, just either won't go or is tough to push into.
The spin down test passed. I can push in the clutch and shift almost immediately into reverse, no need to wait nine seconds.
It's the shifting into second gear that is really getting me concerned. Its just not right. If I shift it slowly it will grind terribly. If I shift it quickly it goes in without grinding but it's very rough. I think I may have to bring the car to the transmission shop that rebuilt the trans. Problem is I brought them the transmission to rebuild without the whole car so I feel like they may blame the issues on something else.


RMIII
1996 Suzuki X-90 2wd manual 16valve 1.6l

I must correct myself as it is reverse that doesn't have a synco. The OM does states that you can shift into first under 20 mph but I have never done this, I have never had a need. There is also mention of DBL clutching to shift into first if there is a difficulty.


I believe that this is the first time that you said that you had this trans rebuilt. I think you answered your own question.
B95

 

[Bear95]

He mentioned it in post #9, but only in passing, didn't go into any detail.

I stand corrected again! Oh well, such is life.
B95