Suzuki Burgman 400 - Service manual > Clutch and movable driven face

1) Hold the clutch housing using the special tool and remove the clutch housing nut (1) and remove the clutch housing (2).

Special tool (A): 09930-40113 (Rotor holder)

2) Remove the clutch shoe and movable driven face assembly (3).

Installation

Refer to "Drive V-belt Inspection".

Install the V-belt type continuously variable automatic transmission in the reverse order of the removal. Pay attention to the following points:

Clutch and movable driven face

1) Assemble the clutch shoe, movable driven face assembly and V-belt.

! CAUTION

• Position the V-belt so that its arrow points to the engine rotational direction.
• Degrees the V-belt contact surface (pulley face).

2) Fit the V-belt by compressing it and pushing open the driven face assembly.

! CAUTION Keep compressing the center of V-belt so as not to open apart.

3) Apply grease to the O-ring.

: Grease 99000-25010 (SUZUKI SUPER GREASE A or equivalent)

4) Hold the clutch housing using the special tool and tighten the clutch housing nut (1) to the specified torque.

! CAUTION

• Degrees the clutch housing surface.
• Replace the O-ring with a new one.

Special tool (A): 09930-40113 (Rotor holder)

Tightening torque
Clutch housing nut (a): 85 N*m (8.5 kgf-m, 61.5 lb-ft)

Movable drive face assembly

1) Install the movable drive face assembly (1).

! CAUTION Degrees the V-belt contact face (pulley surface).

2) Install the fixed drive face (2).

3) Install the washer (3) and fixed drive face nut (4).

! CAUTION

• Check for dirt or grease on the fixed drive face and if any, clean and degrees thoroughly. Also check that the parts are properly fitted with the spline.
• When installing the fixed drive face, check that the V-belt has a play and the fixed drive face contacts the end of the spacer.
• When installing the fixed drive face nut, check that the V-belt is not caught in the movable drive face assembly.

4) Hold the fixed drive face using the special tools and tighten the fixed drive face nut (4) to the specified torque.

! WARNING

• To prevent the fin from breakage or injury from occurring due to inadvertent slipping, engage the tool end with the side of pulley securely and make sure the contact is on a center area of the fin.
• Tighten the drive face nut with pressing the special tool to the drive face.

Special tool
(A): 09920-53740 (Clutch sleeve hub holder)
(B): 09920-31020 (Extension handle)

Tightening torque
Fixed drive face nut (a): 105 N*m (10.5 kgf-m, 76.0 lb-ft)

5) Continue to turn the fixed drive face until it moves simultaneously with the movable driven face in order to have the V-belt broken in.

See also: