Clutch Release System

CLUTCH RELEASE SYSTEM

DISMOUNTING AND REMOUNTING OF TRANSMISSION
Refer to Manual Transmission/Transaxle; Service and Repair.

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 and hammer. Release shaft seal will also be pushed out.
Special Tool
(A): 09922-46010
5. Remove release shaft.





6. For removal of No. 1 bush, tap it by using M16 x 1.5 tap.





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

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.
Special Tool
(A): 09943-88211
(B): 09923-46020 or the like
"A": SUZUKI SUPER GREASE A, 99000-25010
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 as in removal.
"A": SUZUKI SUPER GREASE A
Special Tool
(C):09922-46010
4. Coat grease to shaft seal and then install it till it is flush with case surface. Use special tool for this installation and face seal lip downward (inside).
"A": SUZUKI SUPER GREASE A
Special Tool
(D): 09925-98221
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, 99000-25010
8. Apply small amount of grease to input shaft spline and front end as well.
"B": SUZUKI SUPER GREASE I, 99000-25210
9. Install release shaft cover.





10. Set release arm to release shaft aligning their punch marks, then tighten bolt.
Tightening Torque
(a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)





11. If clutch cable bracket has been removed or replaced, install it with 2 bolts.
Tightening Torque
(b): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)