Clutch Cover and Clutch Disc Removal and Installation

Clutch Cover and Clutch Disc Removal and Installation

Clutch Cover and Clutch Disc Components

Removal

1) Dismount manual transaxle assembly. Manual Transaxle Unit Dismounting and Remounting
2) Hold flywheel stationary with special tool and remove clutch cover bolts (1), clutch cover (2) and clutch disc.
Special Tool

(A): 09924-17811





Installation

Clutch Cover and Clutch Disc Inspection

NOTE:

Before installation, make sure that flywheel surface and pressure plate surface are cleaned and dried thoroughly.

1) Hold flywheel with special tool (A).
2) Install clutch disc and clutch cover (1) to flywheel temporarily.
3) Align center of clutch disc and center of flywheel using special tool (B).
4) Install and tighten clutch cover bolts using the following procedures:
a) Tighten 3 bolts (3) by hand.
b) Tighten other 3 bolts (4) evenly and gradually to 5.0 Nm (0.51 kgf-m, 4.0 lbf-ft).
c) Fully tighten all bolts (3), (4) evenly and gradually to specified torque in numerical order ("1" - "6") starting from bolt nearby strut plate rivet (2).

NOTE:
Tighten the clutch cover bolts while checking that the special tool can slide smoothly.

Special Tool

(A): 09924-17811

(B): 09923-37910

Tightening torque
Clutch cover bolt* (a): 5.0 Nm -> 23 Nm (0.51 kgf-m -> 2.3 kgf-m, 4.0 lbf-ft -> 17.0 lbf-ft)
Clutch cover bolt* (b): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)





5) Slightly apply grease to input shaft (1), and then join manual transaxle assembly with engine. Manual Transaxle Unit Dismounting and Remounting

"A" Grease: 99000-25210 (SUZUKI Super Grease I)

NOTE:
When inserting transaxle input shaft to clutch disc, turn crankshaft little by little to match the spline.