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PostPosted: Sat Jan 05, 2013 11:32 pm 
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Joined: Fri Sep 17, 2010 10:04 pm
Posts: 33
Location: north carolina
So, I did the swap,slapped it together and the clutch doesn't disengage properly.

Here's my thought:

the 1.3 Aluminum flywheel is a little thinner than the stock 1.0.
Could it be the throwout bearing isn't pushing far enough to disengage?
Would you put an adapter plate or something behind the flywheel to bring it out to the stock position?
Any help would be appreciated :D


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PostPosted: Sun Jan 06, 2013 4:21 am 
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Location: lake stevens, wa
No spacer is necessary. Its a straight forward swap. Could you explain in more detail the problems. Is clutch dragging a little or will it not engage at all? Have you tried tightening the pedal adjustment nut?

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PostPosted: Sun Jan 06, 2013 8:47 am 
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Joined: Fri Sep 17, 2010 10:04 pm
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Location: north carolina
Thanks for the reply hammer.
I did adjust the cable nut full tight. The clutch seems to work when the car isn't running.It will engage and disengage. When you start it and try to put it in gear it grinds. It actually stays engaged if you start it in first,clutch in or out-so the car lunges.
I guess there was one thing I thought was odd. The fingers on the pressure plate are depressed after I attached it to the flywheel. I didn't know if this was normal or not? it seems like that would be the engage position? It seems like they would point out a little instead of being flat?


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PostPosted: Sun Jan 06, 2013 12:24 pm 
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Location: columbus, ohio
there's a "knee" point for those pressure plate fingers and typically, you would have some light pressure applied by the throwout bearing on the fingers with the actuating arm all the way back on a new clutch.

it sounds as if the clutch is dragging a little. you should try to adjust the cable a bit to get it to fully disengage.

another thing, i would suppose that you replaced the pilot bearing with the new one from the clutch kit. i've had those go bad which caused enough drag on the transmission's input shaft to make gear changes crunchy.

on the cable adjustment, you should have free play when the pedal is all the way up. look at the clutch arm where it fits onto the splines that stick up from the bell housing. there's a dot punched into the shaft and a line on the clutch arm. those are the index marks and they should line up to get the correct clutch arm angle.

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PostPosted: Sun Jan 06, 2013 1:08 pm 
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Joined: Fri Sep 17, 2010 10:04 pm
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Location: north carolina
Thanks, I'm going out to the garage!
I'll let you know how it goes


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PostPosted: Sun Jan 06, 2013 2:38 pm 
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Joined: Fri Sep 17, 2010 10:04 pm
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Location: north carolina
It has got to be the wrong clutch! and/or pressure plate
When you attach the pressure plate to the flywheel it compresses on the clutch plates so it makes the pressure plate fingers flat. So it seems like there is no room left to push the fingers to disengage.
I was this initially concerned but,put it together anyways, and sure enough,it didn't work :huh:
It is a suzuki rd flywheel,the one they sell on their site. Maybe I should have gotten the clutch from them? Andi told me to just get a stock 1.3 gt clutch. O'rielly's gave me the wrong one the first time.Maybe they did it again...who knows. Everything lined up but that...
HELP! This shit is driving me nuts!


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PostPosted: Mon Jan 07, 2013 9:32 pm 
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Joined: Fri Sep 17, 2010 10:04 pm
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Location: north carolina
Ok,ordered a new clutch today...comes in tomorrow
Napa has been the best source for regular parts-a little more expensive though
Anyone else have a good source for regular parts?
I'm talking about the 1.3 gt parts?


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PostPosted: Mon Jan 07, 2013 10:08 pm 
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Joined: Sat Mar 27, 2004 4:15 pm
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Location: Brantford, Ontario, Canada
if you can wait a few days

rockauto.com

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PostPosted: Tue Jan 08, 2013 1:30 am 
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Joined: Tue Feb 21, 2006 10:47 pm
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Location: burlington,ontario
Can you post some pictures or a video so we can get some visual reference to the problem.
I would have pulled everything apart again before going out and getting another clutch kit and make sure everything is there and working right.

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PostPosted: Thu Jan 10, 2013 3:13 am 
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Joined: Fri Sep 17, 2010 10:04 pm
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Location: north carolina
Ok...I pulled everything apart again...several friggin times
I have never had soo much trouble!
I ended up shimming the pressure plate/diaphram out about 0.6mm
I test drive in the morning,I'll report back :mrgreen:
All the canadians are in here eh?
That's cool, I grew up in st. catharines...
Thanks for the rock auto plug :wink:


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PostPosted: Thu Jan 10, 2013 3:34 am 
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Location: Christchurch NZ, quake capital
On that flywheel is there a step between the mounting holes for the clutch cover and the actual clutch clamping surface? as it sounds like the clutch surface area is a little too thick for that particular clutch cover, try a different brand of clutch kit, could be a case of manufacturing tolerances since neither the flywheel or clutch is oem anymore, I'm picking it's the flywheel.
Also make sure your clutch pedal has a 5-10mms of free play before it starts pulling cable.


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PostPosted: Thu Jan 10, 2013 7:18 am 
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Joined: Tue Oct 19, 2010 9:16 am
Posts: 412
Location: sidney, nebraska
Your pressure plate fingers/diaphram is suspose to compress. Thats how it clamps everything together. make sure you dont have the clutch disk in backwards. Some setups will bolt together but not function.

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PostPosted: Thu Jan 10, 2013 10:14 pm 
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Joined: Fri Sep 17, 2010 10:04 pm
Posts: 33
Location: north carolina
Alright!
drove the little bugger all over today!-runs like a top
I couldn't give'r too much,I'm breaking in a rebuild also.
So,here's what I did(guidance from Andi@suzuki RD)
I shimmed the diaphram out 0.06mm(little washers) and it worked like a charm.
A lot of friggin work though...live and learn :huh:
Anyways,hopefully this might help someone who might get caught up in this scenario.
Thanks for all the help Dudes---team work! :wink:


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