Forward and Direct Clutch Assembly Installation

Reference: DIRECT CLUTCH PISTON TRAVEL CHECK 

Reference: FORWARD CLUTCH PISTON TRAVEL CHECK 

Fig 1: Identifying Forward Clutch And Direct Clutch Assembly

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1. Install the forward clutch and direct clutch assembly (23). Rotate the clutch assembly during installation in order to index the forward and direct clutch plates with the rear internal gear and the rear sun gear assembly.
   Fig 2: Identifying Installation Height Of Forward Clutch And Direct Clutch Assembly

   Courtesy of SUZUKI OF AMERICA CORP.
2. Measure dimension a.

   Installation Height 

   Dimension a should be 50.850-51.825 mm (2.002-2.040 in). 

3. If dimension a is greater than specification, index the forward and direct clutch assembly until the correct specification is met.
   Fig 3: Identifying Lube Fluid Pipe

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   NOTE: Do not bend or damage the lube fluid pipe.
4. Using a plastic hammer, install the lube fluid pipe (85).
   Fig 4: Identifying Lube Fluid Pipe Retainer

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5. Install the lube fluid pipe retainer (84)
   CAUTION: Refer to FASTENER NOTICE .
6. Install the lube fluid pipe retainer bolt (83).

   Tightening torque 

   Tighten the lube fluid pipe retainer bolt to 5 N.m (44 lb in). 

   Fig 5: Identifying Case Fluid Passage Seals

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7. Apply grease to the 5 new case fluid passage seals.
8. Install the 5 new case fluid passage seals (86) into the transmission case assembly.

   Reference: FORWARD AND DIRECT CLUTCH END PLAY MEASUREMENT