Forward Clutch Disassembly and Assembly: Assembly

Reference: BEARING AND RACE INSTALLATION SPECIFICATION

Apply A/T fluid to new forward input shaft O-rings, install forward clutch piston and piston return spring (2) to forward input shaft and then install retaining return spring ring (1) with special tool and hydraulic press.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.
NOTE:
- When installing return spring (2), be careful so that return spring will not fall or tilt.
- Do not align opening in retaining ring (1) with lug of forward clutch piston return spring at its retainer section.
Special Tool

(A): 09926-98310

Fig 1: Installing Retaining Return Spring Ring
Courtesy of SUZUKI OF AMERICA CORP.
Install clutch discs and plates and then install retaining clutch ring.
NOTE:
- Refer to FORWARD CLUTCH COMPONENTS when installing each component.
- Do not match opening in retaining clutch ring and dent in forward clutch input shaft.
Install bearing races (1) and thrust bearing (2).

Fig 2: Identifying Bearing Races And Thrust Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install forward clutch hub (3), direct clutch hub (2) and retaining ring (1) in that order.

Fig 3: Identifying Forward Clutch Hub, Direct Clutch Hub And Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.

Install forward clutch (2) to O/D case (1). Apply compressed air (400 - 800 kPa, 4 - 8 kgf/cm² , 57 - 113 psi) to oil hole at the right of cut in O/D case and measure movement of forward clutch piston. If measured value is not within standard range, select another plate with suitable thickness from the list below and replace it.

Standard forward clutch piston movement

1.40 - 1.70 mm (0.055 - 0.067 in.)

FORWARD CLUTCH PISTON SPECIFICATION

Thickness
1.75 - 1.85 mm (0.069 - 0.073 in.)
1.95 - 2.05 mm (0.077 - 0.081 in.)

Fig 4: Measuring Movement Of Forward Clutch Piston

Courtesy of SUZUKI OF AMERICA CORP.