Clutch Drum & Input Shaft Assembly Reassembly

WARNING: This page is about a different variant/trim than selected.

Reference: BEARING AND RACE INSTALLATION DIAGRAM

Reference: CLUTCH DRUM & INPUT SHAFT ASSEMBLY INSPECTION

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

Fig 1: Identifying O-Rings
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Install clutch balancer No.2 (1) and direct clutch return spring (2) to direct clutch piston sub assembly.

Fig 2: Identifying Clutch Balancer No.2 & Direct Clutch Return Spring
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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: Identifying O-Ring
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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

(A): 09926-96040

CAUTION:
Be careful when applying pressure, for overpressure will cause direct clutch return spring to deform.

Fig 4: Applying Pressure To Clutch Return Spring With Special Tool
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: Identifying Snap Ring Gap Between Snap Ring Stoppers Of Clutch Balancer
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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: Identifying O-Ring
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Press-fit clutch drum sub assembly (1) into reverse clutch piston (2) by hands.
CAUTION:
Do not twist or deviate O-rings during installation.

Fig 7: Identifying Clutch Drum Sub Assembly With Reverse Clutch Piston
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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 8: Identifying O-Ring With Reverse Clutch Return Spring
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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

(A): 09926-96040

Fig 9: Identifying Special Tool On Clutch Balancer No. 3
Courtesy of SUZUKI OF AMERICA CORP.
Set end gap of snap ring (1) in piston.

Fig 10: Identifying Snap Ring Gap Specifications
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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 - P - D
Install direct clutch flange "F".

Fig 11: Identifying Direct Clutch Plates & Discs
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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 12: Aligning Snap Rings Gap With Cut Portion Of Clutch Drum Sub Assembly
Courtesy of SUZUKI OF AMERICA CORP.

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 Fig 13.

Direct clutch pack clearance

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)

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 DIRECT CLUTCH FLANGE THICKNESS SPECIFICATION TABLE below and replace it.

DIRECT CLUTCH FLANGE THICKNESS SPECIFICATION TABLE

Identification No.	Thickness	Identification No.	Thickness
0	3.0 mm (0.118 in.)	5	3.5 mm (0.138 in.)
1	3.1 mm (0.122 in.)	6	3.6 mm (0.142 in.)
2	3.2 mm (0.126 in.)	7	3.7 mm (0.146 in.)
3	3.3 mm (0.130 in.)	8	3.8 mm (0.150 in.)
4	3.4 mm (0.134 in.)	-	-

Fig 13: Applying Compressed Air Into Oil Hole Of Oil Pump

Courtesy of SUZUKI OF AMERICA CORP.

Install reverse clutch flange (1).

Fig 14: Identifying 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: Identifying Reverse Clutch Reaction Sleeve & Clutch Cushion Plate
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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 clutch drum sub assembly.

Fig 16: Aligning Snap Ring Gap With Cut Portion Of Clutch Drum Sub Assembly
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 Fig 17.

Pack Clearance

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)

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 REVERSE CLUTCH FLANGE THICKNESS SPECIFICATION TABLE below and replace it.

REVERSE CLUTCH FLANGE THICKNESS SPECIFICATION TABLE

Identification No.	Thickness	Identification No.	Thickness
0	2.8 mm (0.110 in.)	6	3.4 mm (0.134 in.)
1	2.9 mm (0.114 in.)	7	3.5 mm (0.138 in.)
2	3.0 mm (0.118 in.)	8	3.6 mm (0.142 in.)
3	3.1 mm (0.122 in.)	9	3.7 mm (0.146 in.)
4	3.2 mm (0.126 in.)	A	3.8 mm (0.150 in.)
5	3.3 mm (0.130 in.)	-	-

Fig 17: Applying Compressed Air Into Oil Hole Of Oil Pump

Courtesy of SUZUKI OF AMERICA CORP.

Remove snap ring (1) from clutch drum sub assembly by using flat end rod or the like.

Fig 18: Identifying Snap Ring From Clutch Drum Sub Assembly
Courtesy of SUZUKI OF AMERICA CORP.
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 19: Identifying Reverse Clutch Reaction Sleeve
Courtesy of SUZUKI OF AMERICA CORP.
Apply A/T fluid to new 2 O-rings (1) and then install O-rings to forward clutch piston.

Fig 20: Identifying O-Rings 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 21: Identifying O-Ring To Clutch Balancer No.1
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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 22: Identifying Forward Clutch Piston, Clutch Balancer No.1 & Forward Clutch Return Spring
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.).

Special Tool

(A): 09926-96520

Fig 23: Compressing Clutch Balancer No.1 With Special Tool
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 24: Identifying Snap Ring Gap Between Snap Ring Stoppers
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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 25: Identifying Clutch Plates, Forward Clutch Flange & Clutch Discs
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 input shaft assembly.

Fig 26: Aligning Snap Ring Gap With Cut Portion Of Input Shaft Assembly
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 27: Identifying Oil Seal Rings To Input Shaft Groove
Courtesy of SUZUKI OF AMERICA CORP.

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 Fig 28.

Pack Clearance

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)

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 FORWARD CLUTCH FLANGE THICKNESS SPECIFICATION TABLE below and replace it.

FORWARD CLUTCH FLANGE THICKNESS SPECIFICATION TABLE

Identification No.	Thickness	Identification No.	Thickness
0	3.0 mm (0.118 in.)	6	3.6 mm (0.142 in.)
1	3.1 mm (0.122 in.)	7	3.7 mm (0.146 in.)
2	3.2 mm (0.126 in.)	8	3.8 mm (0.150 in.)
3	3.3 mm (0.130 in.)	9	3.9 mm (0.154 in.)
4	3.4 mm (0.134 in.)	A	4.0 mm (0.158 in.)
5	3.5 mm (0.138 in.)	-	-

Fig 28: Applying Compressed Air Into Oil Hole Of Input Shaft

Courtesy of SUZUKI OF AMERICA CORP.

Install input shaft assembly (1) to clutch drum assembly.

Fig 29: Identifying Input Shaft Assembly
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Install thrust needle roller bearing (1) to clutch drum assembly.

Fig 30: Identifying 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 31: Identifying Thrust Bearing Race No.2 & Input Shaft Thrust Bearing Race
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Install forward clutch hub (1) to clutch drum assembly.

Fig 32: Identifying Forward Clutch Hub
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Install 2 thrust needle roller bearings (1) to direct clutch hub.

Fig 33: Identifying Thrust Needle Roller Bearings
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Install direct clutch hub (1) to clutch drum assembly.

Fig 34: Identifying 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 - P - D
Install reverse clutch flange "F".
Install clutch cushion plate (1) to reverse clutch hub.

Fig 35: Identifying Clutch Cushion Plate
Courtesy of SUZUKI OF AMERICA CORP.
Install reverse clutch reaction sleeve (1) to reverse clutch hub.

Fig 36: Identifying 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 37: Identifying 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 38: Identifying Snap Ring On Clutch Drum & Input Shaft Assembly
Courtesy of SUZUKI OF AMERICA CORP.