Clutch Drum & Input Shaft Assembly Inspection

Reference: CLUTCH DRUM & INPUT SHAFT ASSEMBLY DISASSEMBLY 

Reference: CLUTCH DRUM & INPUT SHAFT ASSEMBLY REASSEMBLY 

• Check that sliding surface of discs, plate and flange are not worn or burnt. if necessary, replace them.
  NOTE:

  • If disc lining is exfoliated, discolored or worn hardly, replace all discs.
  • If only a part of printed numbers is corroded, replace all discs.
  • Before assembling new discs, soak them in A/T fluid for at least 15 minutes.
    Fig 1: Identifying Discs

    Courtesy of SUZUKI OF AMERICA CORP.
• Measure inside diameter of reverse clutch hub bushing. If inside diameter exceeds limit, replace reverse clutch hub.

  Reveres clutch hub bushing inside diameter 

  Standard: 35.812 - 35.837 mm (1.4099 - 1.4109 in.) 

  Limit: 35.887 mm (1.4129 in.) 

  Fig 2: Measuring Inside Diameter Of Reverse Clutch Hub Bushing

  Courtesy of SUZUKI OF AMERICA CORP.
• Measure inside diameter of direct clutch hub bushing. If inside diameter exceeds limit, replace direct clutch hub.

  Direct clutch hub bushing inside diameter 

  Standard: 26.037 - 26.062 mm (1.0251 - 1.0261 in.) 

  Limit: 26.112 mm (1.028 in.) 

  Fig 3: Measuring Inside Diameter Of Direct Clutch Hub Bushing

  Courtesy of SUZUKI OF AMERICA CORP.
• Measure free length of forward clutch return spring including spring seat.

  Forward clutch return spring free length 

  "a": 26.74 mm (1.053 in.) 

  NOTE:

  • Do not apply excessive force when measuring spring free length.
  • Perform measurement at several points.
  Fig 4: Measuring Free Length Of Forward Clutch Return Spring

  Courtesy of SUZUKI OF AMERICA CORP.
• Measure free length reverse clutch return spring including spring seat.

  Reverse clutch return spring free length 

  "a": 21.04 mm (0.828 in.) 

  NOTE:

  • Do not apply excessive force when measuring spring free length.
  • Perform measurement at several points.
  Fig 5: Measuring Free Length Reverse Clutch Return Spring

  Courtesy of SUZUKI OF AMERICA CORP.
• Measure free length direct clutch return spring including spring seat.

  Direct clutch return spring free length 

  "a": 19.51 mm (0.768 in.) 

  NOTE:

  • Do not apply excessive force when measuring spring free length.
  • Perform measurement at several points.
  Fig 6: Measuring Free Length Direct Clutch Return Spring

  Courtesy of SUZUKI OF AMERICA CORP.