1987 SUZUKI GRAND VITARA Service Repair Manual

11-2. REMOVALRemoval of clutch presupposes that the trans-
mission has been dismounted according to the
method outlined in SECTION 13 TRANS-
MISSION.
Clutch Cover and Disc
Remove 6 bolts securing clutch cover to fly-
wheel, and take off clutch cover and disc.
Fig. 1 l-3@ Special tool (Flywheel holder
09924- 17810)
Clutch Release Bearing Remove clutch release bearing from transmission
input shaft bearing retainer.
Input Shaft End Bearing
Use bearing remover (special tool) for removal
of this bearing.
1.Special tool (Bearing remover 09917-58010)
2. Input shaft bearing
Fig. 11-5
Clutch Release Shaft Bushes
For replacement of bushes, refer to p. 13-5
of SECTION 13 TRANSMISSION.
Fig. 11-4
11-4

Clutch Disc Facing Surface Condition
A burnt or glazed (glass-like surface) facing can
be reconditioned by grinding it with No. 120 -
200 sandpaper. If surface is in bad condition
beyond repair, replace whole clutch disc assemb-
ly.
11-3. INSPECTION OF COMPONENTSBacklash in Disc Setration Fit
Check backlash by turning disc back and forth
as mounted on transmission input shaft. Replace
disc assembly if backlash is noted to exceed
service limit. Backlash here is a circular displace-
ment as measured with a dial indicator.
Fig. 1 l-6 @ Sandpaper
Clutch Facing Wear
Check wear of facing by measuring depth of
each rivet head depression, i.e. distance between
rivet head and facing surface. If depressing is
found to have reached service limit at any of the
holes, replace clutch disc assembly.
Rivet head
depression
Standard
1.2mm
(0.05 in.)
Service limit
0.5 mm
(0.02 in.)
Backlash in serration fitService limit
0.8 mm (0.03 in.)
Fig. 11-8
Clutch Cover
Inspect clutch cover for evidence of diaphragm
spring rivets getting loose. If rivets are loose
or are getting loose, replace cover assembly as
such cover makes rattling noise when clutch
pedal is depressed.
Inspect tips of tapering fingers (to which the
release bearing exerts a push to disengage clutch)
for wear. If tips are worn excessively, replace
cover assembly.
Fig. 1 l-7
Fig. 1 l-9@ Spring wear; @ Rivet
11-5

Release Bearing
Replace release bearing if it sticks, rattles or
makes abnormal noise when spun anaturned by
hand.
Fig. 11-10
Input Shaft Bearing
Replace input shaft bearing if it sticks, rattles or
makes abnormal noise when spun and turned by
hand.
Flywheel
Check surface contacting clutch disc for any
wear or damage.
Fig. 11-12
Fig. 1 I- 11
11-6

114. INSTALLATION
Install clutch by reversing removal procedure.
Some important steps will be explained below.
Flywheel
1) Tighten bolts to specification.
1.Flywheel
2.Flywheel bolt
3.Special tool (Flywheel holder 09924-l 7810)
Fig. 11-13 4*Input shaft bearing
2) Install input shaft end bearing to flywheel
using bearing installer (special tool).
1. Input shaft bearing2. Special tool (Input shaft bearing installer 09925-98210)
Fig. 1 l- 13- 1
Clutch Disc and Clutch Cover
Using special tool (clutch center guide), install
clutch disc and clutch cover.
Tighten clutch cover bolts to specification using
special tool (Flywheel holder).
1.2.
3.
4.
Fig. 1 l-14
Special tool (Clutch center guide 09923-38220)
Clutch cover
Clutch cover boltSpecial tool (Flywheel holder 09924-l 7810)
Clutch Release Bearing
Before installing retainer, apply grease to its
inner surface.
Fig. 1 I- 15 @ Grease (SUZUKI SUPER
GREASE “A’,)
11-7

Clutch Release Shaft Fork
Apply grease to end of fork.
Fig. I l- 16 @ Grease (SUZUKI SUPER
GREASE “‘A “)
Clutch Release Arm
Align two punch marks when installing clutch
release arm on clutch release shaft.
Fig. 11-17
Clutch Release Shaft Bushes
For reinstallation of bushes, refer to p. 13-5 in
SECTION 13 TRANSMISSION of this manual.
Transmission
For remounting transmission, refer to p. 13-4 in
SECTION 13 TRANSMISSION of this manual
and reverse dismounting procedure.
11-5. MAINTENANCE SERVICES
Clutch Pedal Height
Adjust height of clutch pedal with clutch pedal
stop bolt so that pedal is level with brake pedal.
Tighten lock nut after adjusting.
.
4
I-
I- 18
1. Clutch cable2. Lock nut3. Adjust bolt4. Clutch pedalFig. 1
Clutch Pedal Free Travel
1) Depress clutch pedal, stop the moment
clutch resistance is felt, and measure distance
(clutch pedal free travel). Free travel should
be within the following specification.
!Clutch pedal free travel20-30mm
(0.8 - 1.1 in.)c
Fig. 1
1. Clutch pedalfree travel
Before remounting transmission ass’y, apply
grease (SUZUKI SUPER GREASE I) to input
shaft. Refer to Fig. 13-84.
11-8

2) If free travel is out of specification, adjust it
with clutch cable outer nuts.
NOTE:
After adjusting free travel, make sure that the
clutch cable end protrudes at least 5 mm from
joint nut
1.Clutch cable joint nutAt least 5 mm (0.196 in.)
Fig. 1 l-20
Clutch Cable Routing
1) For left-hand side steering vehicle.
Clutch Cable Lubrication
Apply grease to hook part @ of clutch cable.
Clutch cable
1 Clutch pedaly-v
Fig. 11-21
Warm air hose
box -
Jadk
15-i0N.m1.5 - 2.0 kg-m
SteeTing shaft’Viewed from arrow “6”
4-7N.m
2.9- 5.0lb-ft
Steerina shaft
/ -
\. Radiator stayI, ,IViewed from arrow A-
40 - 60 N.m4.0 - 6.0 kg-m
I
Fig. 1 l-221
11-9

2) For right-hand side steering vehicle.
Air cleaner outlethoseAircleaner
Radiator outlet
Air cleaner outlet hose
Clutch cable
Cla&p
Viewed from arrow “A”
40 - 60 N.m4.0 - 6.0 kg-m
I
Viewedfrom arrow“6”
Radiator
Fig. 11-23
Warmair hoseViewed from arrow “C”
11-6. RECOMMENDED TORQUE SPECIFICATION
Be sure to torque each nut or bolt, if loosened, to specification given below.
If specified tightening torque for particular bolt or nut is not included here, refer to p. O-12 of this manual.
Fastening PartsTightening torque
, N.mkg-mlb-ft
1.Flywheelbolts57-655.7-6.541.5-47.0
2.Clutchcover bolts18-281.B-2.613.5-20.0
3.Clutchrelease armboltandnutlo- 161.O-1.67.5-11.5.
11-10

SECTION 12
GEAR SHIFTING CONTROL
CONTENTS
12-1. GENERAL DESCRIPTION
12-2. REMOVAL . . . . .; . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .
GEAR SHIFT LEVER. . . . . . . . . . . . . .. . . . . . . . . .. . . . , . . . . .. . . .
GEAR SHIFT LEVER SELECT GUIDE PINS. . . . . . . . . . . . . . . . . . . . .
12-3. INSPECTION OF ‘COMPONENTS . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
GEAR SHIFT LEVER . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .
REVERSE & LOW SPEED SELECT GUIDE PINS..................
GEAR SHIFT FORK SHAFT................................
12-4. INSTALLATION. . . . . . . . . . . . . . . . . .. . . . . . . . * . . . . . . . . . .. . . . .
REVERSE & LOW SPEED GUIDE PINS......................
GEAR SHIFT LEVER CASE.................................
GEAR SHIFT CONTROL LEVER SEAT. . . ....................
TIGHTENING TORQUE & GREASING POINT. . . . . . . . . . . . . . . . . . .
12-1
...............................12-2
12-3
12-3
12-3
12-4
12-4
12-4
12-4
12-5
12-5
12-5
12-6
12-6
12