Clutch Pedal Assembly: Service and Repair

MAINTENANCE SERVICE
Clutch Pedal Height





Adjust clutch pedal height with adjust bolt located on pedal bracket so that clutch pedal height exceeds brake pedal height by 15 mm (0.6 inch) and tighten lock nut.

Height difference "a": 15 mm (0.6 inch)

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 following specification.

Pedal free travel "b": 15 - 20 mm (0.6 - 0.8 inch)





2. If free travel is out of specification, adjust it with cable joint nut.

Release lever free travel "c": 0 - 2 mm (0 - 0.08 inch)

3. After checking clutch pedal free travel, also check clutch for proper function with engine running.


INSTALLATION

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





1. Install flywheel to crankshaft and tighten bolts to specification.

Special Tool (A): 09924 - 17810

Tightening Torque (a): 78 Nm (7.8 kg-m, 56.5 ft. lbs.)





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

Special Tool (B): 09925 - 98210





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

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

Special Tool
(A): 09924 - 17810
(C): 09923 - 36330

Tightening Torque (b): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)





4. Slightly apply grease to input shaft, then join transmission assembly with engine.

"A": SUZUKI SUPER GREASE I, 99000 - 25210

NOTE: Turn crankshaft a little through flywheel gear while inserting transmission input shaft to clutch disc until splines mesh.