Forward and Direct Clutch End Play Measurement

Reference: FORWARD AND DIRECT CLUTCH ASSEMBLY INSTALLATION 

Reference: 1-2-REVERSE CLUTCH PISTON TRAVEL MEASUREMENT 

Special Tool 

J 45200 Dial Indicator Set 

Fig 1: Identifying Transmission Case Cover Assembly And Transmission Case Assembly

Courtesy of SUZUKI OF AMERICA CORP.

1. Install the transmission case cover assembly (19) to the transmission case assembly (17).
   Fig 2: Measuring Forward And Direct Clutch End Play

   Courtesy of SUZUKI OF AMERICA CORP.
2. Rotate the transmission case so that the front section of the case is facing up.
3. Install J 45200 as shown and set the dial indicator to zero.
   NOTE: Excessive upward pressure will cause an incorrect reading.
4. With one hand, carefully pull straight up on the forward and direct clutch assembly (23) input shaft until the assembly first bottoms out.
5. Record the measurement.
   Fig 3: Identifying Forward Clutch Housing Selective Thrust Bearing Race

   Courtesy of SUZUKI OF AMERICA CORP.
6. Compare the measurement with the listed specification.

   Specification 

   Forward and direct clutch assembly end play: 0.188 - 0.570 mm (0.007 - 0.022 in) 

7. If out of specification, remove the transmission case cover assembly.
8. Replace the forward clutch housing selective thrust bearing race (628) as needed to obtain the correct end play specification.
   Fig 4: Identifying Transmission Case Cover Assembly And Transmission Case Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
9. If the end play measurement is within specifications, rotate the transmission case assembly so that the transmission case cover side is facing up.
10. Remove the transmission case cover assembly (19) and clean the sealing surfaces of the transmission case cover (19) and the transmission case assembly (17).

    Reference: TRANSMISSION CASE COVER AND 1-2 REVERSE CLUTCH ASSEMBLY INSTALLATION