Clutch Cover and Clutch Disc Removal and Installation

Clutch Cover and Clutch Disc Removal and Installation
Reference: Clutch Cover and Clutch Disc Components

Removal
1) Dismount manual transaxle assembly.
2) Hold flywheel with special tool and remove clutch cover bolts (1), clutch cover (2) and clutch disc.

Special Tool
(A): 09924-17811





Installation
Reference: 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) Align clutch disc with crankshaft center using special tool (B) and install clutch cover (1).
3) 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:
While tightening clutch cover bolts, make sure that clutch disk spline is centered.

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)





4) Slightly apply grease to input shaft (1), and then join manual transaxle assembly with engine.

"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.