Pressure Plate: Service and Repair

Clutch Cover, Clutch Disc and Flywheel Removal and Installation

Removal
1) Dismount transmission assembly referring to Manual Transmission Assembly 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





3) Pull out input shaft bearing (1) by using special tools.

Special Tool
(A): 09921-26020
(B): 09930-30104








4) Remove flywheel from crankshaft.

Installation

NOTE:
Before installation, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.

1) Install flywheel (1) to crankshaft and tighten new bolts (2) to specification.

Special Tool
(A): 09924-17811

Tightening torque
Flywheel bolt (a): 70 Nm (7.1 kg-m, 52.0 lbf-ft)





2) Using special tool, install input shaft bearing to flywheel.

Special Tool
(B): 09925-98210





3) Aligning clutch disc to flywheel center by using special tool, install clutch cover (1) and bolts (2). Then tighten bolts to specification.

NOTE:
^ While tightening clutch cover bolts, compress clutch disc with special tool by hand so that disc centered.
^ Tighten cover bolts little by little evenly in diagonal order.

Special Tool
(A): 09924-17811
(C): 09923-36320

Tightening torque
Clutch cover bolt (b): 23 Nm (2.3 kg-m, 17.0 lbf-ft)





4) Slightly apply grease to input shaft (1).

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

5) Join transmission assembly with engine.
Refer to Manual Transmission Assembly Dismounting and Remounting.

NOTE:
Turn crankshaft with wrench from front while inserting transmission input shaft (1) to clutch disc until splines mesh.