Clutch Release System

REMOVAL
1. Remove release arm by loosening its bolt.
2. Take out release bearing by turning release shaft.
3. Unhook return spring by using pliers.





4. Drive out No.2 bush by using Special Tool (A): 09922-46010, or equivalent and hammer. Release shaft seal will also be pushed out.
5. Remove release shaft.





6. For removal of No. 1 bush, tap it by using M 16 x 1.5 tap.





7. Leaving tap in No. 1 bush, screw in joint pipe over tap, join sliding shaft with joint pipe, and then drive out bush using Special Tool (B): 09923-46020 and (C): 09930-30102, or equivalent.

INSPECTION
1. Check clutch release bearing for smooth rotation.
2. Inspect smoothness of release bearing retaining portion of transmission case and correct or replace right case as necessary.

CAUTION: Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage.

INSTALLATION





1. Drive in a new No. 1 bush by using adequate drive handle and hammer and then apply grease to bush inside using Special Tool (A): 09943-88211 and (B): 09923-46020 or the like.

"A": SUZUKI SUPER GREASE A, or equivalent

2. Install release shaft with return spring applied to it.





3. Apply grease to No.2 bush inside and press-fit it by using the same Special Tool (C): 09922-46010, or equivalent as in removal.

"A": SUZUKI SUPER GREASE A, or equivalent.

4. Coat grease to shaft seal and then install it till it is flush with case surface. Use Special Tool (D): 09925-98221, or equivalent for this installation and face seal lip downward (inside).

"A": SUZUKI SUPER GREASE A, or equivalent.

5. Caulk seal at A by using caulking tool and hammer.





6. Hook return spring.
7. Apply grease to release bearing inside and release shaft arm, then set bearing.

"A": SUZUKI SUPER GREASE A, or equivalent.

8. Apply small amount of grease to input shaft spline and front end as well.

"B": SUZUKI SUPER GREASE A, or equivalent.





9. Set release arm to release shaft aligning their punch marks, then tighten bolt.

Tightening Torque (a): 13 Nm (9.5 ft. lbs.)





10. If clutch cable bracket has been removed or replaced, install it with 2 bolts.

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