Clutch Drum & Input Shaft Assembly Reassembly: Notes

Apply A/T fluid to new 2 O-rings (1) and then install O-rings to direct clutch piston.

Fig 1: Applying A/T Fluid To New O-rings
Courtesy of SUZUKI OF AMERICA CORP.
Install clutch balancer No.2 (1) and direct clutch return spring (2) to direct clutch piston sub assembly.

Fig 2: Installing Clutch Balancer
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Apply A/T fluid to new O-ring (1), and then install O-ring to clutch drum sub assembly.
Press-fit direct clutch piston into clutch drum by hands.

Fig 3: Pressing Fit Direct Clutch Piston Into Clutch Drum
Courtesy of SUZUKI OF AMERICA CORP.
Compress clutch balancer No.2 (1) until the clutch balancer No.2 is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool and hydraulic press.
Special tool
1. (A): 09926-96040
CAUTION: Be careful when applying pressure, for overpressure will cause direct clutch return spring to deform.

Fig 4: Compressing Clutch Balancer
Courtesy of SUZUKI OF AMERICA CORP.
Install snap ring (1) as set snap ring end gap between snap ring stoppers (2) of clutch balancer No.2.

Fig 5: Installing Snap Ring
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Apply A/T fluid to new O-ring (1), and then install O-ring to reverse clutch piston sub assembly.

Fig 6: Installing O-Ring To Reverse Clutch Piston Sub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Press-fit clutch drum sub assembly (1) into reverse clutch piston (2) by hands. See Figure .
CAUTION: Do not twist or deviate O-rings during installation.
Apply A/T fluid to new O-ring (1), and then install O-ring to reverse clutch piston sub assembly.
Install reverse clutch return spring (2) onto reverse clutch piston sub assembly.

Fig 7: Installing Reverse Clutch Return Spring
Courtesy of SUZUKI OF AMERICA CORP.
Place clutch balancer No.3 (1) onto reverse clutch piston sub assembly.
CAUTION: Do not twist or deviate O-ring during installation.
Compress clutch balancer No.3 (1) until the clutch balancer No.3 is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool and hydraulic press, and then install snap ring.
CAUTION: Be careful when applying pressure, for overpressure will cause reverse clutch return spring to deform.

Special tool
1. (A): 09926-96040
Fig 8: Compressing Clutch Balancer
Courtesy of SUZUKI OF AMERICA CORP.
Set end gap of snap ring (1) in piston as shown in figure.

Fig 9: Setting End Gap Of Snap Ring In Piston
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Install direct clutch plates "P" and direct clutch discs "D" in the following order.
P - P - D - P - D - P - D - P - D
Install direct clutch flange "F".

Fig 10: Installing Direct Clutch Flange
Courtesy of SUZUKI OF AMERICA CORP.
Install 2 snap rings (1) by using flat end rod or the like being sure not to align snap rings end gap with cut portion of clutch drum sub assembly.

Fig 11: Installing Snap Rings
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Measure pack clearance of direct clutch by applying compressed air (392 kPa, 4.0 kg/cm² , 57 psi) into oil hole (1) of oil pump (2) as shown in figure.
Direct clutch pack clearance
1. 0.50 - 0.80 mm (0.020 - 0.031 in.)
NOTE: Install a selective flange (t 3.4 mm) when measuring the moving distance. (shaded area in figure.)
- Flange moving distance A: 0.36 - 1.242 mm (0.0141 - 0.0489 in.)
  Piston stroke: Flange moving distance A - 0.15 mm (0.0059 in.)
  
  If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Fig 12: Identifying Available Direct Clutch Flange Thickness Chart (1 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.

Fig 13: Identifying Available Direct Clutch Flange Thickness Chart (2 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse clutch flange (1).

Fig 14: Installing Reverse Clutch Flange
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Install reverse clutch reaction sleeve (1), clutch cushion plate (2), reverse clutch flange "F", reverse clutch discs "D" and reverse clutch plates "P" in the following order.
D - P - D - P - D - P - D - P - D - F

Fig 15: Installing Reverse Clutch Reaction Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Install snap ring (1) by using flat end rod or the like being sure not to align snap ring end gap with cut portion of clutch drum sub assembly.

Fig 16: Installing Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Measure reverse clutch piston stroke (A) and the moving distance (B) of reverse clutch flange at the both end across a diameter by applying compressed air (392 kPa, 4 kg/cm² , 57 psi) into oil hole (1) of oil pump (2) as shown in figure.
Pack Clearance
1. 0.5 - 0.8 mm (0.020 - 0.031 in.)
NOTE: Install selective flange (t 3.3 mm) when measuring the moving distance. (shaded area in figure)
- Piston stroke A: 1.69 - 2.81 mm (0.0665 - 0.11 in.)
  Flange moving distance B: 1.20 - 1.68 mm (0.0472 - 0.0661 in.)
  
  Pack clearance: Piston stroke A - Flange moving distance B - 0.16 mm (0.0063 in.)
  
  If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Fig 17: Identifying Available Reverse Clutch Flange Thickness Chart (1 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.

Fig 18: Identifying Available Reverse Clutch Flange Thickness Chart (2 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.
Remove snap ring (1) from clutch drum sub assembly by using flat end rod or the like.

Fig 19: Removing Snap Ring
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Remove reverse clutch reaction sleeve (1), clutch cushion plate (2), reverse clutch flange "F", reverse clutch discs "D" and clutch plates "P" from clutch drum sub assembly.

Fig 20: Removing Reverse Clutch Reaction Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Apply A/T fluid to new 2 O-rings (1), and then install O-ring to forward clutch piston.

Fig 21: Installing O-Ring To Forward Clutch Piston
Courtesy of SUZUKI OF AMERICA CORP.
Apply A/T fluid to new O-ring (1), and then install O-ring to clutch balancer No.1.

Fig 22: Installing O-Ring To Clutch Balancer
Courtesy of SUZUKI OF AMERICA CORP.
Install forward clutch piston (1), clutch balancer No.1 (3) and forward clutch return spring (2).
CAUTION: Do not twist or deviate O-rings during installation.

Fig 23: Installing Forward Clutch Piston
Courtesy of SUZUKI OF AMERICA CORP.
Compress clutch balancer No.1 (1) until the clutch balancer No.1 is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove by using special tool and hydraulic press.
CAUTION: Be careful when applying pressure, for overpressure will cause forward clutch return spring to deform.

NOTE: Set special tool to the width of "a" 68 mm (2.652 in.) as shown in figure.

Special tool
1. (A): 09926-96520
Fig 24: Compressing Clutch Balancer
Courtesy of SUZUKI OF AMERICA CORP.
Install snap ring as set snap ring end gap between snap ring stoppers (2) of clutch balancer No.1.

Fig 25: Installing Snap Ring
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Install forward clutch flange "F".
Install clutch plates "P", forward clutch flange "F" and clutch discs "D" in the following order.
D - P - D - P - D - P - D - F

Fig 26: Installing Clutch Plates
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Install snap ring (1) by using flat end rod or the like being sure not to align snap ring end gap with cut portion of input shaft assembly.

Fig 27: Installing Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Apply A/T fluid to 3 oil seal rings (1).
Squeeze the ends of 3 oil seal rings (1) together, and then install oil seal rings to input shaft groove.
CAUTION: Do not spread seal excessively.
Check seals rotate smoothly.

Fig 28: Checking Seals Rotate Smoothly
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Measure forward clutch pack clearance (A) by applying compressed air (392 kPa, 4.0 kg/cm² , 57 psi) into oil hole, (1) of input shaft as shown in figure.
Pack Clearance
1. 0.4 - 0.7 mm (0.016 - 0.027 in.)
NOTE: Install a selective flange (t 3.4 mm) when measuring the moving distance. (shaded area in figure.)
- Flange moving distance A: 0.12 - 1.19 mm (0.00472 - 0.0468 in.)
  Pack Clearance: Flange moving distance A - 0.01 mm (0.00039 in.)
  
  If pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Fig 29: Identifying Available Forward Clutch Flange Thickness Chart (1 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.

Fig 30: Identifying Available Forward Clutch Flange Thickness Chart (2 Of 2)
Courtesy of SUZUKI OF AMERICA CORP.
Install input shaft assembly (1) to clutch drum assembly.

Fig 31: Installing Input Shaft
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Install thrust needle roller bearing (1) to clutch drum assembly.

Fig 32: Installing Thrust Needle Roller Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install thrust bearing race No.2 (1) and input shaft thrust bearing race (2) to forward clutch hub.

Fig 33: Installing Thrust Bearing Race
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Install forward clutch hub (1) to clutch drum assembly.

Fig 34: Installing Forward Clutch Hub
Courtesy of SUZUKI OF AMERICA CORP.
Install 2 thrust needle roller bearings (1) to direct clutch hub.

Fig 35: Installing Thrust Needle Roller Bearings
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Install direct clutch hub (1) to clutch drum assembly.

Fig 36: Installing Direct Clutch Hub
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Install reverse clutch plates "P" and reverse clutch discs "D" to reverse clutch hub in the following order.
D - P - D - P - D - P - D
Install reverse clutch flange "F".
Install clutch cushion plate (1) to reverse clutch hub as shown in figure.

Fig 37: Installing Clutch Cushion Plate
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse clutch reaction sleeve (1) to reverse clutch hub.

Fig 38: Installing Reverse Clutch Reaction Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse clutch hub sub assembly (1) including reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 4 reverse clutch discs and 3 reverse clutch plates to clutch drum assembly.

Fig 39: Installing Reverse Clutch Hub Sub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
Install snap ring (1) on clutch drum and input shaft assembly by using flat end rod or the like.

Fig 40: Installing Snap Ring
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