09440-52003 Suzuki CLUTCH DOG SHIFTER SPRING

1. Use a bar as shown to remove tension from belts, then remove belts (1). 2. Disconnect spring from arm assembly (3) then remove spring (2). 3. Remove air baffle group (4). 4. Remove two bolts (5), then remove bracket assembly (6) from the automatic timing advance cover. 5. Fasten a hoist to the fan drive and belt tightener. Remove the bolts (7) that hold the fan drive and belt tightener to the timing gear cover. Remove fan drive and belt tightener (8). Weight of the unit is 168 lb. (76 kg).Install Fan Drive And Belt Tightener
1. Fasten a hoist to the fan drive and belt tightener (1) and put it in position on the timing gear cover as shown. Install the bolts that hold it to the timing gear cover. 2. Put spring bracket assembly (2) in position on the automatic timing advance cover and install the bolts that hold it. 3. Install air baffle group (4). Connect spring (3) to the bracket and arm assembly. 4. Install fan belts (5). See LUBRICATION AND MAINTENANCE GUIDE for correct belt tension.end by:a) install fanDisassemble Fan Drive And Belt Tightener
start by:a) remove fan drive and belt tightener 1. Remove bolt (1) and plate (2), then remove belt tightener (3) from the fan drive bracket. 2. Remove two bolts (4) and washer (5) from the fan drive hub. 3. Remove hub assembly (6) from bracket assembly (7) as a unit. 4. Remove six bolts (9) and remove pulley (8) from hub assembly. 5. Remove O-ring seal (14), bearing (13), spacer (12), bearing (11) and seal (10) from the pulley housing. 6. Remove sleeve (15) from arm assembly if necessary. Sleeve (15) will be damaged if removed. 7. Remove four bolts (16), then remove cover (17). Remove gasket from cover. 8. Remove bolt (18) and washer (19) from pulley. 9. Remove pulley assembly (20) from arm assembly. If necessary use tooling (A) to remove the pulley assembly (20). 10. Remove bearing (23), spacer (22), bearing (24) and seal (21) from pulley housing. 11. Remove internal snap ring (25) from the pulley housing.Assemble Fan Drive And Belt Tightener
1. Install internal snap ring (1) in the pulley housing. 2. Install inner bearing (2) in pulley housing. 3. Install seal on bracket side of pulley with tool group (A). Install seal with the lip toward the arm assembly and hub. 4. Put pulley assembly (4) in position on the arm assembly. Install spacer (5) over shaft. Install bearing (3) in bore of pulley.5. Fill the cavity between bearings with 5P960 Multipurpose Type Grease. 6. Install washer and bolt (6) on arm shaft. 7. Install a new gasket on cover (7). Install cover (7) on the pulley assembly with four bolts. 8. Heat sleeve (8) to a maximum temperature of 275°F (135°C) and install it on arm assembly. 9. Install bearing in hub assembly (9) with tool group (B). 10. Install seal in hub assembly with tool group (B). Install seal with lip toward the bracket. 11. Install hub assembly (9) on bracket assembly. Install spacer (10) in hub with end of spacer with groove toward bracket. 12. Install bearing (11) in hub assembly.13. Fill the cavity between bearings with 5P960 Multipurpose Type Grease. 14. Install washer (12) and two bolts on bracket shaft. 15. Fasten a hoist to the fan drive pulley (13) and install the pulley on hub assembly with the six bolts that hold it. 16. Install belt tightener pulley on arm assembly. Install plate, washer and bolt that hold pulley on arm assembly.end by:a) install fan drive and belt tightener