Caution
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Note the conical curve side of spring washer (11) faces outside. |
Special tool
(a): 09920–53740 (clutch sleeve hub
holder)
Tightening torque clutch sleeve hub nut (a): 95 n·m (9.5 Kgf-m, 68.7 Lbf-ft)
Note thrust washer (15) is located between the pressure plate and bearing (14). |
Note insert the outermost no. 1 Drive plate claws “a” to the other slits “b” of clutch housing as shown in the figure. |
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Note two kinds of drive plate (no. 1 And no. 2) Are equipped in the clutch system, they can be distinguished by inside diameter. |
Note three kinds of the driven plate (no. 1, No. 2 And no. 3) Are equipped in the clutch system, they can be distinguished by color and thickness. The no. 1, No. 2 And no. 3 Driven plates are 8 pcs. In total. 5 – 7 Pcs. Of no. 1 Driven plates are used with 1 pc. Of no. 2 And 0 – 2 pc(-s). Of no. 3 Driven plate(-s) as a set. The no. 3 Driven plate(-s) should be installed in pressure plate side. |
Note when install the pressure plate, fit the convex part “d” of the pressure plate onto the concave part “e” of the clutch sleeve hub. |
Tightening torque clutch spring set bolt: 10 n·m (1.0 Kgf-m, 7.0 Lbfft)
Note tighten the clutch spring set bolt little by little and diagonally. |
Tightening torque clutch release adjusting screw lock-nut: 6 n·m ( 0.6 Kgf-m, 4.5 Lbf-ft)
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
Caution use new gasket to prevent oil leakage. |
: Sealant 99000–31140 (suzuki
bond
no.1207B or equivalent)
M/o: molybdenum oil (molybdenum oil solution)
Note fit new gasket washer to the bolt “f” and clamp to the bolt “g”. |
Fuel pressure inspection
Keep away from fire or spark.
Spilled gasoline should be wiped off
immediately.
Work in a well-ventilated area.
Inspect the fuel pressure in the following procedures:
lift and support the fuel tank. Refer to “fuel tank removal and
installati ...
Side-stand / ignition interlock system parts
inspection
Check the interlock system for proper operation. If the
interlock system does not operate properly, check each
component for damage or abnormalities. If any
abnormality is found, replace the component with a new
one.
Side-stand switch
Turn the ignition switch off.
Remove the left si ...
Transmission removal
Remove the engine assembly from the frame. Refer to “engine assembly
removal” in section 1d .
Remove the engine top side. Refer to “engine top side disassembly” in
section 1d .
Separate the upper and lower crankcases. Refer to “engine bottom side
disassembly” in section 1 ...