Oil Pump, 2nd Brake and 2nd Coast Brake Inspection

Reference: OIL PUMP, 2ND COAST BRAKE AND 2ND BRAKE DISASSEMBLY AND REASSEMBLY 

1. Check body clearance of driven gear (1).

   Push driven gear (2) to one side of oil pump body (3). Using a feeler gauge, measure clearance between driven gear (2) and body (3). If clearance exceeds standard value, replace oil pump assembly.

   Clearance between driven gear and body 

   Standard: 0.075 - 0.15 mm (0.00295 - 0.0059 in.) 

   Limit: 0.20 mm (0.0079 in.) 

   Fig 1: Measuring Clearance Between Driven Gear & Body

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2. Check tip clearance of both drive and driven gears.

   Measure radial clearance between gear tooth tip and crescent (1). If clearance exceeds standard value, replace oil pump assembly.

   Clearance between drive gear and crescent 

   Standard: 0.004 - 0.248 mm (0.0001 - 0.010 in.) 

   Limit: 0.298 mm (0.0117 in.) 

   Fig 2: Measuring Radial Clearance Between Gear Tooth Tip & Crescent

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3. Check side clearance of both gears.

   Using a straightedge (1) and a feeler gauge, measure side clearance between gears and pump body. If clearance exceeds standard value, replace oil pump assembly.

   Side clearance between gears and oil pump body 

   Standard: 0.03 - 0.05 mm (0.001 - 0.002 in.) 

   Fig 3: Measuring Side Clearance Between Gears & Pump Body

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4. Measure inside diameter of oil pump body bushing, using special tools.

   If inside diameter exceeds limit, replace oil pump body.

   Oil pump body bushing inside diameter limit: 

   38.18 mm (1.503 in.) 

   Special Tool 

   1. 09900-20607 
   2. 09900-22403 
   NOTE: Perform measurement at several points.
   Fig 4: Measuring Inside Diameter Of Oil Pump Body Bushing

   Courtesy of SUZUKI OF AMERICA CORP.
5. Measure inside diameter of starter shaft bushing, using special tools.

   If inside diameter exceeds limit, replace starter shaft.

   Starter shaft bushing inside diameter limit: 

   21.57 mm (0.849 in.) 

   Special Tool 

   1. 09900-20607 
   2. 09900-22403 
   NOTE: Perform measurement at several points.
   Fig 5: Measuring Inside Diameter Of Starter Shaft Bushing

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6. Check that sliding surface of friction, separator and cushion plates are not worn or burnt.

   If necessary, replace.

   NOTE:

   • If friction plate lining is exfoliated, discolored or worn hardly, replace all friction plates.
   • Before assembling new friction plates, soak them in A/T fluid for at least two hours.
   Fig 6: Identifying Friction Plates

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7. Measure height of 2nd brake return spring and 2nd coast brake return spring. If necessary, replace.

   2nd brake return spring height 

   Standard: 25.17 mm (0.99 in.) 

   2nd coast brake return spring height 

   Standard: 14.47 mm (0.57 in.) 

   NOTE: Do not apply excessive force when measuring spring height.
   Perform measurement at several points.
   Fig 7: Measuring Height Of 2nd Brake Return Spring

   Courtesy of SUZUKI OF AMERICA CORP.