Clutch: Service and Repair

CLUTCH COVER, CLUTCH DISC AND FLYWHEEL
Removal





1. Hold flywheel stationary with special tool and remove clutch cover bolts, clutch cover and clutch disc.

Special Tool
(A): 09924-17810





2. Pull out input shaft bearing by using special tool and wrench.

Special Tool
(B): 09917-58010

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 1.2 mm (0.05 inch) Service limit 0.5 mm (0.02 inch)
"b": Standard 1.5 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.

Special Tool
(A): 09924-17810

Tightening Torque
(a) 75 - 80 Nm (7.5 - 8.0 kg-m, 54.5 - 57.5 ft. lbs.)





2. Using special tool, install input shaft bearing to flywheel.

Special Tool
(B): 09925-98210





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 (clutch center guide) by hand so that disc is centered.
^ Tighten cover bolts little by little evenly in diagonal order.

Special Tool
(A): 09924-17810
(C): 09923-36330

Tightening Torque
(b): 18 - 28 Nm (1.8 - 2.8 kg-m, 13.5 - 20.0 ft. lbs.)





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

"A": SUZUKI SUPER GREASE I, 99000-25210

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