Direct Clutch Disassembly and Assembly: Assembly

Reference: DIRECT CLUTCH INSPECTION 

Reference: BEARING AND RACE INSTALLATION SPECIFICATION 

Assemble each component by reversing disassembly procedure and noting the following points.

• Always use new O-ring and apply A/T fluid before installation.
• Do not align opening in retaining ring (2) with lug of direct clutch piston return spring at retainer.
  CAUTION: Be careful when applying pressure, for overpressure will cause plate section of piston return spring to deform.

  Special Tool 

  (A): 09926-98310 

  Fig 1: Installing Retaining Return Spring Ring

  Courtesy of SUZUKI OF AMERICA CORP.
• Use care so that direct clutch piston return spring will not fall or tilt.
• Do not match opening (1) in retaining back plate ring with cutout (2) in direct clutch cylinder.
  Fig 2: Identifying Cutout In Direct Clutch Cylinder

  Courtesy of SUZUKI OF AMERICA CORP.
• Install clutch backing plate with its grooved side (1) facing the front.
  Fig 3: Identifying Clutch Backing Plate Grooved Side

  Courtesy of SUZUKI OF AMERICA CORP.
• Install direct clutch assembly (1) to center support (2) and with compressed air (400 - 800 kPa, 4 - 8 kgf/cm² , 57 - 113 psi) applied to oil hole (3), measure stroke of direct clutch piston as shown in figure.

  If it is not within standard range, select another plate with suitable thickness from the list below and replace it.

  PLATE THICKNESS SPECIFICATION
  
  

  Identification No.	Thickness
  No identification	3.925 - 4.050 mm (0.155 - 0.159 in.)
  "B"	3.675 - 3.800 mm (0.145 - 0.150 in.)
  "A"	3.475 - 3.600 mm (0.137 - 0.142 in.)

  Direct clutch piston standard stroke 

  0.90 - 1.30 mm (0.035 - 0.051 in.) 

  Fig 4: Measuring Stroke Of Direct Clutch Piston

  Courtesy of SUZUKI OF AMERICA CORP.