Direct Clutch Disassembly and Reassembly: Reassembly

Reference: DIRECT CLUTCH INSPECTION 

Reference: BEARING AND RACE INSTALLATION SPECIFICATION 

Reassemble 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.
  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.

  Special Tool 

  (A): 09926-98310 

  Fig 1: Removing Retaining Ring Using Tool

  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 Retaining Back Plate Ring Opening And Direct Clutch Cylinder Cutout

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

  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.

  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 Direct Clutch Piston Stroke Using Tools

  Courtesy of SUZUKI OF AMERICA CORP.