Diagnostic Information And Procedures; Clutch System Symptom Diagnosis; Repair Instructions; Clutch Pedal Inspection - Suzuki Swift Sport 2004 Service & Repair Manual

5C-2 Clutch:

Clutch System Symptom Diagnosis

Condition
Slipping
Dragging clutch
Clutch vibration
Noisy clutch
Grabbing clutch

Clutch Pedal Inspection

Cylinder Push Rod Play "A"
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
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).

Diagnostic Information and Procedures

Possible cause
Improper clutch pedal free travel
Worn or oily clutch disc facing
Warped disc, pressure plate or flywheel
surface
Weakened diaphragm spring
Master cylinder piston or seal cup not
returning
Improper clutch pedal free travel
Weakened diaphragm spring, or worn
spring tip
Rusted input shaft splines
Damaged or worn splines of transaxle
input shaft
Excessively wobbly clutch disc
Clutch facings broken or dirty with oil
Fluid leakage
Glazed (glass-like) clutch facings
Clutch facings dirty with oil
Release bearing slides unsmoothly on
input shaft bearing retainer
Wobbly clutch disc, or poor facing
contact
Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose
Distorted pressure plate or flywheel
surface
Weakened engine mounting
Loosened engine mounting bolt or nut
Worn or broken release bearing
Input shaft front bearing worn down
Excessive rattle of clutch disc hub
Cracked clutch disc
Pressure plate and diaphragm spring
rattling
Clutch disc facings soaked with oil
Clutch disc facings excessively worn
Rivet heads showing out of facing
Weakened torsion springs

Repair Instructions

S7RS0B5306001
Correction / Reference Item
Replace master cylinder or clutch pedal arm.
Replace disc.
Replace disc, clutch cover or flywheel.
Replace clutch cover.
Replace master cylinder.
Replace master cylinder or clutch pedal arm.
Replace clutch cover.
Lubricate.
Replace input shaft.
Replace disc.
Replace disc.
Repair or replace.
Repair or replace disc.
Replace disc.
Lubricate or replace input shaft bearing
retainer.
Replace disc.
Replace disc.
Replace clutch cover or flywheel.
Replace engine mounting.
Retighten engine mounting bolt or nut.
Replace release bearing.
Replace input shaft bearing.
Replace disc.
Replace disc.
Replace clutch cover.
Replace disc.
Replace disc.
Replace disc.
Replace disc.
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 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.
S7RS0B5304001