Clean and Inspection

Special Tool 

J 45185 Bore Gauge Set 

Fig 1: Measuring Inner Diameter Of 4-5 Clutch Drum Bushing

Courtesy of SUZUKI OF AMERICA CORP.

1. Wash the clutch components in clean solvent and air dry.
2. Inspect the clutch drum for the following conditions:
   • Lugs in the drum for excessive grooves that prevent the clutch plates from sliding
   • Sun gear for chips or metal embedded in the teeth
   • Drum surface for scoring or excessive wear
   • Piston o-ring surfaces for wear, nicks, or scratches
   • Bearing thrust surfaces for damage or wear
3. Using J 45185, measure the inner diameter of the 4-5 clutch drum bushing (A) at different locations and take the average.

   Specification 

   36.125 - 36.200 mm (1.422 - 1.425 in) 

4. If the bushing is out of specifications or any of the above conditions are found replace the 4-5 clutch drum
   Fig 2: Applying Compressed Air In Opposite Side Of Check Valve

   Courtesy of SUZUKI OF AMERICA CORP.
5. Shake the clutch piston to inspect the ball check valve for not being stuck.
6. Apply compressed air in the opposite side of the check valve and inspect for leaking.
7. Inspect the piston o-ring seal grooves for damage.
8. Replace the piston if any of the above conditions are found.
9. Inspect the clutch plates and discs for wear, warp age, or being burnt.
10. Replace the clutch plates and discs if any of the above conditions are found.

Reference: 4-5 CLUTCH DRUM ASSEMBLY ASSEMBLE .