5C
Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation
Reference: Clutch Cover, Clutch Disc, Flywheel and Release Bearing Components:K9K Model
Removal
1) Dismount transmission assembly referring to Manual Transmission Assembly Dismounting and Remounting:K9K Model .
2) Hold flywheel with special tool and remove clutch cover bolts (1) and take off clutch cover (2) and disc.
Special Tool
(A) : 09916–98110
3) Hold flywheel (1) with special tool and remove flywheel bolts (2) and take off flywheel with spacer (3).
Special Tool
(A) : 09916–98110
4) Remove input shaft bearing from crankshaft by hand, if necessary.
5) Remove release bearing (1) and clutch release fork (2).
Installation
Reference: Clutch Cover, Clutch Disc, Flywheel and Release Bearing Inspection:K9K Model
NOTE:
Before assembling, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.
1) Apply grease to release bearing (1) inner surface and release fork (2).
“A” : Grease 99000–25010 ( SUZUKI Super Grease A )
2) Install input shaft bearing to crankshaft.
3) Install flywheel (1) with spacer (3) to crankshaft as shown in figure and tighten bolts (2) to specified torque.
Special Tool
(A) : 09916–98110
Tightening torque
Flywheel bolt ( a ): 55 N·m ( 5.5 kg-m, 40.0 lb-ft)
[A]: Flywheel side
4) Using special tool, install clutch disc and clutch cover (1).
Tighten clutch cover bolts (2) to specification using special tool.
NOTE:
• While tightening clutch cover bolts, compress clutch disc with special tool (A) by hand so that disc centered.
• Tighten cover bolts little by little evenly in diagonal order.
Special Tool
(A) : 09923–36320
(B) : 09916–98110
Tightening torque
Clutch cover bolt ( a ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
5) Install release bearing (1) and clutch release fork (2).
6) Slightly apply grease to input shaft. Then join transmission with engine. Refer to Manual Transmission Assembly Dismounting and Remounting:K9K Model .
“A” : Grease 99000–25210 ( SUZUKI Super Grease I )