Edited by Foxit PDF Editor

Copyright (c) by Foxit Software Company, 2004Clutch: 5C-1

For Evaluation Only.
Clutch
Transmission / Transaxle

General Description
Clutch (Hydraulic Type) Construction
S6RW0C5301001
The clutch is a diaphragm spring clutch of a dry single disc type. The diaphragm spring is of a tapering-finger type,
which is a solid ring in the outer diameter part, with a series of tapered fingers pointing inward.
The disc, carrying four torsional coil springs, is positioned on the transaxle input shaft with an involute spline fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the peripheral edge
part of the spring pushes on the pressure plate against the flywheel (with the disc in between), when the clutch release
bearing (incorporated in clutch operating cylinder) is held back. This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing (incorporated in clutch operating cylinder) to advance and
pushes on the tips of the tapered fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the
pressure plate away from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to
transaxle input shaft. Clutch fluid is supplied from brake fluid reservoir. Clutch fluid level can be checked by brake fluid
level of brake fluid reservoir.

I5RW0A530001-01

1. Crankshaft 4. Pressure plate 7. Operating cylinder assembly

2. Flywheel 5. Clutch cover 8. Input shaft bearing
3. Clutch disc 6. Diaphragm spring 9. Input shaft
 Edited by Foxit PDF Editor
5C-2 Clutch: Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.
Diagnostic Information and Procedures
Clutch System Symptom Diagnosis
S6RW0C5304001

Condition Possible cause Correction / Reference Item

Slipping Improper clutch pedal free travel Bleed air or replace master cylinder.
Worn or oily clutch disc facing Replace disc.
Warped disc, pressure plate or flywheel Replace disc, clutch cover or flywheel.
surface
Weakened diaphragm spring Replace clutch cover.
Master cylinder piston or seal cup not Replace master cylinder.
returning
Dragging clutch Improper clutch pedal free travel Bleed air or replace master cylinder.
Weakened diaphragm spring, or worn Replace clutch cover.
spring tip
Rusted input shaft splines Lubricate.
Damaged or worn splines of transaxle Replace input shaft.
input shaft
Excessively wobbly clutch disc Replace disc.
Clutch facings broken or dirty with oil Replace disc.
Fluid leakage Repair or replace.
Clutch vibration Glazed (glass-like) clutch facings Repair or replace disc.
Clutch facings dirty with oil Replace disc.
Release bearing slides unsmoothly Replace clutch operating cylinder assembly.
Wobbly clutch disc, or poor facing Replace disc.
contact
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose Replace disc.
Distorted pressure plate or flywheel Replace clutch cover or flywheel.
surface
Weakened engine mounting Replace engine mounting.
Loosened engine mounting bolt or nut Retighten engine mounting bolt or nut.
Noisy clutch Worn or broken release bearing Replace clutch operating cylinder assembly.
Input shaft front bearing worn down Replace input shaft bearing.
Excessive rattle of clutch disc hub Replace disc.
Cracked clutch disc Replace disc.
Pressure plate and diaphragm spring Replace clutch cover.
rattling
Grabbing clutch Clutch disc facings soaked with oil Replace disc.
Clutch disc facings excessively worn Replace disc.
Rivet heads showing out of facing Replace disc.
Weakened torsion springs Replace disc.
 Edited by Foxit PDF Editor
Copyright (c) by Foxit Software Company, 2004Clutch: 5C-3
For Evaluation Only.
Repair Instructions
Clutch Pedal Inspection 6) If “c” is not within specification, it is possible that air
S6RW0C5306001 is trapped in this system. If suspected so, bleed air
Cylinder Push Rod Play “a”
referring to “Air Bleeding of Clutch System”. Upon
1) Press clutch pedal (1) gradually with finger, stop completion of above inspection, start engine and
when slight increase of resistance is felt and check clutch for proper operation.
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).

Clutch Pedal Free Travel “b”

1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel “b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.

Clutch Release Margin “c”

1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing. I5RW0A530002-01

5) Measure distance between release point (4) and full

stroke point (5) on clutch pedal (1) which is shown by Clutch Fluid Level Inspection
S6RW0C5306002
“c” in the figure. 1) Check clutch system for crack, damage and fluid
Clutch release margin leakage.
“c”: 25 – 55 mm (0.98 – 2.17 in.) If any faulty is found, repair or replace.
2) Check fluid level referring to “Brake Fluid Level
Inspection in Section 4A”.
 Edited by Foxit PDF Editor
5C-4 Clutch: Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.
Air Bleeding of Clutch System 6) When bubbles stop, depress and hold clutch pedal,
S6RW0C5306003 and tighten bleeder plug.
! CAUTION
Tightening torque
• Brake fluid is extremely damaging to paint. Clutch bleeder plug: 5 N·m (0.5 kgf-m, 4.0 lb-ft)
If fluid should accidentally touch painted
7) Then attach bleeder plug cap.
surface, immediately wipe fluid from paint
and clean painted surface. 8) After completing bleeding operation, apply fluid
pressure to pipe line and check for leakage.
• When operating the pedal stroke for air
bleeding of clutch system, after releasing 9) Replenish fluid into reservoir up to specified level.
the clutch pedal, be sure to wait 1 second
or more before depressing it again.
Otherwise, the oil seal of operating
cylinder will be damaged, resulting in oil
leakage.

Bleeding operation is necessary to remove air whenever

it entered hydraulic clutch system.
1) Fill master cylinder reservoir with brake fluid and
keep at least one-half full of fluid during bleeding
operation.
I7RW01530002-01
Clutch fluid specification 10) Check clutch pedal for sponginess. If found spongy,
: Refer to brake reservoir cap repeat entire procedure of bleeding.

Clutch Pedal Position (CPP) Switch Removal

and Installation
S6RW0C5306004
Removal
1) Disconnect connector of CPP switch (1) with ignition
switch OFF.
2) Remove CPP switch (1) from pedal bracket.

I7RW01530002-01

2) Remove bleeder plug cap. Attach a vinyl tube (1) to

bleeder plug, and insert the other end into container 1
(2).

I7RW01530003-01

2
Installation
I7RW01530001-01
1) Instal CPP switch to pedal bracket.
3) Depress clutch pedal several times, and then while
holding it depressed, loosen bleeder plug about one- 2) Adjust switch position referring to “Clutch Pedal
third to one-half turn. Position (CPP) Switch Inspection and Adjustment”.
4) When fluid pressure in cylinder is almost depleted, 3) Connect connector to CPP switch securely.
retighten bleeder plug.
5) Repeat this operation until there are no more air
bubbles in hydraulic line.
 Edited by Foxit PDF Editor
Copyright (c) by Foxit Software Company, 2004Clutch: 5C-5
For Evaluation Only.
Clutch Pedal Position (CPP) Switch Inspection Adjustment
and Adjustment With clutch pedal (1) depressed, adjust switch (2)
S6RW0C5306005 position so that clearance between end of thread and
clutch pedal arm is within specification and then tighten
Inspection lock nut to specified torque.
Check for resistance between terminals under each
condition below. If check result is not satisfactory, Clearance between end of thread and clutch pedal
replace. arm
“a”: 1.5 – 2.0 mm (0.06 – 0.08 in.)
CPP switch resistance
When switch shaft is pushed (1): Continuity Tightening torque
When switch shaft is free (2): No continuity CPP switch lock nut (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-
ft)

“a”
(a)
2

I5JB0A530006-01

I7RW01530004-02

Clutch Fluid Pipe and Hose Location

S6RW0C5306006

[A] 4
4
3
3
1
1

2 2

I5RW0A530003-02

[A]: RH steering vehicle 3. Clutch reservoir hose

1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
 Edited by Foxit PDF Editor
5C-6 Clutch: Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.
Clutch Fluid Pipe Removal and Installation Clutch Fluid Pipe Inspection
S6RW0C5306007 S6RW0C5306008
Check pipe (1) for damage, dirt and leak. Replace if
Removal check result is not satisfactory.

! CAUTION
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be

disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2). I5RW0A530005-01

[A]: LH steering vehicle

[B]: RH steering vehicle

Clutch Master Cylinder Removal and

2
Installation
7 S6RW0C5306009
Removal
6 1) Clean around brake master cylinder reservoir cap
and take out fluid with syringe or such from brake
master cylinder reservoir.
4 5 2) Disconnect clutch fluid pipe (4) from clutch master
3
cylinder (1) referring to “Clutch Fluid Pipe Removal
and Installation”.
1
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal, and then
remove clutch master cylinder.
2
2

1
I5RW0B530002-03

Installation
Reverse removal procedure for installation noting the
4
following.

! CAUTION

• Do not allow fluid to get on painted

3
surface. I5RW0A530006-01

• Do not allow pipe to contact hard against 3. Brake booster

vehicle body or other parts.

• Install each clamp securely.

• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
 Edited by Foxit PDF Editor
Copyright (c) by Foxit Software Company, 2004Clutch: 5C-7
For Evaluation Only.
Installation 5) Remove clutch operating cylinder assembly from
Reverse removal procedure for installation noting the transaxle.
following.
• Apply grease to push rod tip. 3

“A”: Grease 99000–25100 (SUZUKI Silicone

Grease)

“A”

2
I5RW0A530007-01 I5RW0A530008-01
• Tighten clutch master cylinder nut to specified torque.
Installation
Tightening torque
Clutch master cylinder nut: 13 N·m (1.3 kgf-m, 9.5 1) Install clutch operating cylinder assembly (2) to
lb-ft) transaxle. Tighten new mounting bolts to specified
torque.
Clutch Operating Cylinder Assembly Removal Tightening torque
and Installation Clutch operating cylinder assembly mounting
S6RW0C5306010 bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
! CAUTION
2) Connect clutch fluid pipe (4) to clutch operating
• Do not allow fluid to get on painted cylinder assembly temporarily.
surfaces. It may cause painted surface 3) Install clutch pipe joint sleeve (3) to transaxle
damage. securely and then tighten clutch fluid pipe flare nut
• Do not disassemble clutch operating (1) to specified torque.
cylinder assembly. Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
Removal m, 11.5 lb-ft)
1) Clean around reservoir cap of brake master cylinder
and take out fluid with syringe or such. 3
2) Dismount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
3) Loosen clutch fluid pipe flare nut (1) of clutch
4
operating cylinder assembly (2).
4) Remove clutch pipe joint sleeve (3) from transaxle
and then remove clutch fluid pipe (4).
1, (b)

(a)

2
I5RW0A530009-01
 Edited by Foxit PDF Editor
5C-8 Clutch: Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.
4) Remount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
5) Bleed air from system and check clutch pedal free
travel. Refer to “Air Bleeding of Clutch System” and
“Clutch Pedal Inspection”.

I5RW0B530005-03

Clutch Operating Cylinder Assembly Inspection

S6RW0C5306014
Check clutch fluid leakage, spring for damage and
bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.

Clutch Cover, Clutch Disc and Flywheel Components

S6RW0C5306011

6 (b)

5
2

3 (a)

I6RW0C530001-01

1. Clutch cover 4. Flywheel : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

2. Clutch disc 5. Input shaft bearing : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
3. Clutch cover bolt 6. Flywheel bolt : Do not reuse.
 Edited by Foxit PDF Editor
Copyright (c) by Foxit Software Company, 2004Clutch: 5C-9
For Evaluation Only.
Clutch Cover, Clutch Disc and Flywheel 4) Remove flywheel (1) from crankshaft using special
Removal and Installation tool.
S6RW0C5306012
Special tool
Removal (A): 09924–17810
1) Dismount manual transaxle assembly referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with special tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811

I4RS0A530015-02

Installation

NOTE
I4RS0A530014-01 Before assembling, make sure that flywheel
3) Pull out input shaft bearing (1) from flywheel (2), use surface and pressure plate surface have
the following special tool if necessary. been cleaned and dried thoroughly.

Special tool 1) Install flywheel (2) to crankshaft and tighten new

(A): 09921–26020 bolts (1) to specification.
(B): 09930–30104
Special tool
(A): 09924–17810
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)

I2RH01530023-01

I2RH01530024-01
 Edited by Foxit PDF Editor
5C-10 Clutch: Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.
2) Using special tool, install input shaft bearing to 4) Slightly apply grease to input shaft (1), then join
flywheel (1). manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Special tool
Remounting in Section 5B”.
(B): 09925–98210
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)

NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft little by little to match
the splines.

I4RS0A530016-01

3) Aligning clutch disc to flywheel center using special

tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
1
NOTE
• While tightening clutch cover bolts, “A”
I5RW0A530013-01
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): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)

I4RS0A530017-01
 Edited by Foxit PDF Editor
Copyright (c) by Foxit Software Company, 2004 Clutch: 5C-11
For Evaluation Only.
Clutch Cover and Clutch Disc Inspection Clutch Cover
S6RW0C5306013
1) Check diaphragm spring (1) for abnormal wear or
Clutch Disc damage.
Measure depth of rivet head depression, i.e. distance 2) Inspect pressure plate (2) for wear or heat spots.
between rivet head and facing surface. 3) If abnormality is found, replace clutch cover.
If depression is found to have reached service limit at Do not disassemble it into diaphragm spring and
any of rivet holes (2), replace clutch disc assembly (1). pressure plate.
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)

I3RM0A530015-01

I4RS0A530019-01

Specifications
Tightening Torque Specifications
S6RW0C5307001
Tightening torque
Fastening part Note
N⋅m kgf-m lb-ft
Clutch bleeder plug 5 0.5 4.0 )
CPP switch lock nut 7.5 0.75 5.5 )
Clutch master cylinder nut 13 1.3 9.5 )
Clutch operating cylinder assembly mounting )
10 1.0 7.5
bolt
Clutch fluid pipe flare nut 16 1.6 11.5 )
Flywheel bolt 70 7.0 51.0 )
Clutch cover bolt 23 2.3 17.0 )

NOTE
The specified tightening torque is also described in the following.
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
 Edited by Foxit PDF Editor
5C-12 Clutch: Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.
Special Tools and Equipment
Recommended Service Material
S6RW0C5308001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Silicone Grease P/No.: 99000–25100 )
SUZUKI Super Grease I P/No.: 99000–25210 )

Special Tool
S6RW0C5308002
09921–26020 09923–36320
Bearing remover Clutch center guide (15 mm)
) )

09924–17810 09924–17811
Flywheel holder (drive plate Flywheel holder
stopper)
)/) )/)

09925–98210 09930–30104
Input shaft bearing installer Sliding shaft
) )