Forward Clutch Disassembly and Reassembly: Reassembly

Reference: FORWARD CLUTCH INSPECTION 

Reference: BEARING AND RACE INSTALLATION SPECIFICATION 

1. 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.
   NOTE: Applying excessive pressure when compressing the piston return spring will deform the spring's plate section.
   Do not apply any more pressure than is necessary.
   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 Ring Using Tool

   Courtesy of SUZUKI OF AMERICA CORP.
2. 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.
3. Install bearing races (1) and thrust bearing (2).
   Fig 2: Identifying Bearing Races And Thrust Bearing

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install forward clutch hub (3), direct clutch hub (2) and retaining ring (1) in that order.
   Fig 3: Identifying Input Shaft, Forward Clutch Hub, Direct Clutch Hub And Retaining Ring

   Courtesy of SUZUKI OF AMERICA CORP.
5. 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.) 

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

   Fig 4: Measuring Forward Clutch Piston Movement Using Tools

   Courtesy of SUZUKI OF AMERICA CORP.