Replacement

REMOVAL





1. Hold flywheel stationary with Special Tool (A): 09924-17810, or equivalent. and remove clutch cover bolts, clutch cover and clutch disc.





2. Pull out input shaft bearing by using Special Tool (B): 09917-58010, or equivalent, and wrench.

INSPECTION
Input Shaft Bearing
Check bearing for smooth rotation and replace it if abnormality is found.





Clutch Disc
Measure depth of rivet head depression, i.e. distance between rivet head and facing surface.
If depression is found to have reached service limit at any of holes, replace disc assembly.

Rivet Head Depth"a":
Standard 1.4 mm (0.06 inch)
Service Limit 0.5 mm (0.02 inch)

Clutch Cover
1. Check diaphragm spring for abnormal wear or damage.
2. Inspect pressure plate for wear or heat spots.
3. If abnormality is found, replace it as assembly.
Do not disassemble it into diaphragm and pressure plate.

Flywheel
Check surface contacting clutch disc for abnormal wear or heat spots. Replace or repair as required.

INSTALLATION

NOTE: Before assembling, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.





1. Install flywheel to crankshaft and tighten bolts to specification using Special Tool (A): 09924-17810, or equivalent.

Tightening Torque (a): 78 Nm (56.5 ft. lbs.)





2. Using Special Tool (B): 09925-98210, or equivalent, install input shaft bearing to flywheel.





3. Aligning clutch disc with flywheel center by using special tool, install clutch cover and bolts.
Then tighten bolts to specification.

NOTE:
^ While tightening clutch cover bolts, compress clutch disc with Special Tool (A): 09924-17810 and (C): 09923-36330, or equivalent (clutch center guide) by hand so that disc is centered.
^ Tighten cover bolts little by little evenly in diagonal order.

Tightening Torque (b): 23 Nm (17.0 ft. lbs.)





4. Slightly apply grease to input shaft, then join transmission assembly with engine.

"A": SUZUKI SUPER GREASE I, or equivalent

NOTE: Turn crankshaft a little through flywheel gear while inserting transmission input shaft to clutch disc until splines mesh.