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Topic: Samurai Clutch Adjustment (Read 2555 times) previous topic - next topic

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Samurai Clutch Adjustment
I just picked up an 88 Samurai this weekend and everything seems to be ok, accept there was a horrible noise every time you pressed and let-go of the clutch pedal. Seemed like the cable was making a loud grinding noise. Anyway, I pulled the cable out from the clutch pedal and sprayed as much lube down the cable as I could. Seemed to fix the noise, however I now had another issue.

About 2 inches before the pedal was completely pressed, it just drops to the floor. There still is tension, but not like when you initially press the pedal. Just guessing, I would say that it's not adjusted properly.? Anyone know where to find a good tech article on how to properly adjust the clutch?
Angelheaded hipsters burning for the ancient heavenly connection to the starry dynamo in the machinery of night.  - Ginsberg

  • Mope
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Re: Samurai Clutch Adjustment
Reply #1
The FSM does. You can download a copy here.

www.suzukiinfo.com

It will give ya lots of info on everything. Its really nice to have.

Re: Samurai Clutch Adjustment
Reply #2
You wont fix that noise  >:( ITS GONNA HAPPEN  ;) thats the throw-out bearing, all of them do it in neutral when the clutch is depressed, notice how it stops when you press the clutch, as for the rest adjust  [approve]

  • Surly
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  • All good things...
Re: Samurai Clutch Adjustment
Reply #3

You wont fix that noise  >:( ITS GONNA HAPPEN  ;) thats the throw-out bearing, all of them do it in neutral when the clutch is depressed...


Mine doesn't make any noise when the clutch is depressed, nor should any of them. If you hear a "horrible noise" when you press the clutch pedal, something is wrong.
I must admit I didn't want to hear what Surly had to say!

Re: Samurai Clutch Adjustment
Reply #4
   >:(  Out of the sixteen that ive owned/rebuilt they have all done it when you let off the clutch in neutral and thats with me putting clutch/pressureplate/throwout bearing, the whole nine yards into them, i dunno what you did to make em not do it, Surly. Please share it with me though    Btw not when you PRESS the pedal, Depressed if it makes noise/tries to pull that means your losing springs out of the clutch,  ;D been through that 3 times  ::) LOL   Yep, its a purdy mess ;)

  • Surly
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  • All good things...
Re: Samurai Clutch Adjustment
Reply #5

...they have all done it when you let off the clutch in neutral


That's not what I'm talking about... I'm talking about Niteryder's problem (and I thought you were too):


...there was a horrible noise every time you pressed and let-go of the clutch pedal.


Mine doesn't make any noise when the pedal goes down and up, and very little foot pressure is required. How did I do it?
1) make sure the throwout bearing fork isn't worn or twisted, and the roll pin that holds the bearing isn't broken.
2) make sure the bushings that support the fork in the bellhousing aren't worn out.
3) make sure the throwout bearing slides back and forth freely on the input shaft bearing retainer.
4) Make sure the ground strap from the distributor housing to the firewall is in good shape. If it isn't, the starter will pull current through the clutch cable and burn it up (literally).
5) Always use a genuine Suzuki OEM replacement clutch cable
I must admit I didn't want to hear what Surly had to say!

Re: Samurai Clutch Adjustment
Reply #6
X2 when done properly no noise
One Owner

Re: Samurai Clutch Adjustment
Reply #7


5) Always use a genuine Suzuki OEM replacement clutch cable



I can't stress this enough. Buy it once, or buy the others three or four times.

Re: Samurai Clutch Adjustment
Reply #8
I've had two non OEM, cheap replacement clutch cables cause that same problem (three if you count the first one I replaced). A lot of times the cheap ones get a kink in them.

The pedal moves smooth (but hard to press) until the sheath on the cable is compressed as far as it can, then it gives and the clutch drops. I diagnosed mine by having my boy work the clutch in and out while running my hand down the cable from the firewall to the clutch. I felt a certain spot where the sheath was stretching before that point it felt fine.

Try replacing the clutch cable with a Good OEM one, adjusting it per FSM , and routing the cable so it doesn't happen again. BTW when adjusting the cable at the clutch, don't "twist the cable" as you tighten it up. It's probably time to replace it anyways if you had to lube it to  get rid of the noise.

Surly's post is awesome information, and he's been around samurai's a while :)
Proud parent of a U.S. Navy sailor.