Second Coast Clutch Piston Travel Measurement

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.

Reference: SECOND CLUTCH PISTON TRAVEL MEASUREMENT .

Special Tool

J 45166 Dial Indicator Extension Rod - 8 inch

J 45200 Dial Indicator Set

Fig 1: Applying Compressed Air Into Second Coast Clutch Fluid Passage

Courtesy of SUZUKI OF AMERICA CORP.

WARNING: Wear safety glasses when using compressed air in order to prevent eye injury.

Using the same special tool setup used to measure the second clutch piston travel, relocate the dial indicator J 45200 onto the second coast clutch piston and zero the dial indicator.
Apply compressed air into the second coast clutch fluid passage (B1) and measure the piston stroke. Be sure the piston moves smoothly.
Specification

Second coast clutch piston bore stroke: 1.24 - 1.96 mm (0.049 - 0.077 in)
If the piston stroke is out of specifications, ensure the clutch plates are assembled correctly and not worn.
Remove the tools.
CAUTION: Refer to FASTENER NOTICE .
Install the remaining M6 x 1.0 x 14.5 mm fluid pump cover bolt (231) into the hole where J 45166 (2) was located.
Tightening torque

Tighten the fluid pump cover bolt (231) to 12 N.m (106 lb in) .

Reference: FLUID PUMP INSTALLATION .