Forward and Direct Clutch Inspection

Reference: FORWARD AND DIRECT CLUTCH DISASSEMBLY AND REASSEMBLY 

1. Check that sliding surfaces of friction, separator and retaining plates are not worn or burnt. If necessary, replace.
   NOTE:

   • If friction plate lining is exfoliated, discolored or worn hardly, replace all friction plates.
   • Before assembling new friction plates, soak them in A/T fluid for at least two hours.
   Fig 1: Identifying Friction Plates

   Courtesy of SUZUKI OF AMERICA CORP.
2. Measure height of direct clutch piston return spring.

   Forward clutch return spring height 

   Standard: 23.59 mm (0.93 in.) 

   NOTE: Do not apply excessive force when measuring spring height. Perform measurement at several points.
   Fig 2: Measuring Height Of Direct Clutch Piston Return Spring

   Courtesy of SUZUKI OF AMERICA CORP.
3. Check that ball makes creaking noise when shaking forward clutch piston and direct clutch piston. (i.e., check that ball is free.)
4. Check that there is no leakage from backside of oil hole (1) by applying low pressure air.
   Fig 3: Identifying Oil Hole

   Courtesy of SUZUKI OF AMERICA CORP.