Clutch Release System

Removal
1. Remove release arm by loosening its bolt.
2. Take out release bearing by turning release shaft.





3. Drive out No.2 bush by using special tool and hammer. Release shaft seal will also be pushed out.
Special tool (A): 09922-46010
4. Remove release shaft (1).





5. Pull No.1 bush out by using special tools.
Special tool
(B): 09925-46010
(C): 09930-30102

Installation





1. Drive in a new No. 1 bush (1) 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 (1) inside and press-fit it by using the same special tool as in removal.
"A": SUZUKI SUPER GREASE A 99000-25010
Special tool (C): 09922-46010
4. Coat grease to shaft seal (2) 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 99000-25010
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 (1) inside and release shaft arm (2), then set bearing.
"A": SUZUKI SUPER GREASE A 99000-25010
8. Apply small amount of grease to input shaft (3) spline and front end as well.
"B": SUZUKI SUPER GREASE I 99000-25210





9. Set release arm to release shaft aligning their punch marks, then tighten nut (1).
Tightening torque
Release arm nut (a): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)

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.