Clutch Release System Removal and Installation: Installation

Reference: CLUTCH RELEASE SYSTEM INSPECTION 

1. Drive in a new No. 1 bush (1) by using special tools and hammer and then apply grease to bush inside.

   Special Tool 

   1. 09943-88211 
   2. 09923-46020 

   "A": Grease 99000-25010 

2. Install release shaft.
   Fig 1: Installing Release Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
3. Apply grease to No. 2 bush (1) inside and press-fit it by using the same special tool as in removal.

   "A": Grease 99000-25010 

   Special Tool 

   1. 09922-46010 
4. Coat grease to release shaft (3) oil 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": Grease 99000-25010 

   Special Tool 

   1. (B): 09925-98221 
5. Caulk seal at A by using caulking (4) tool and hammer.
   Fig 2: Applying Grease To Bush

   Courtesy of SUZUKI OF AMERICA CORP.
6. Apply grease to release bearing inside diameter and release shaft arm (2), then set release bearing (1).

   "A": Grease 99000-25010 

7. Apply small amount of grease to input shaft (3) spline and front end as well.

   "B": Grease 99000-25210 

   Fig 3: Applying Grease To Input Shaft Spline

   Courtesy of SUZUKI OF AMERICA CORP.
8. Set release arm to release shaft aligning their punch marks (1), then tighten nut (2) and bolt.

   Tightening torque 

   Release arm nut (a): 23 N.m (2.3 kg-m, 17.0 lb-ft) 

   Fig 4: Aligning Punch Marks

   Courtesy of SUZUKI OF AMERICA CORP.