Suzuki Club UK

Hi guys,

Been a lurker on the forum for a while and usually find what I need by searching. But I have a problem with my clutch which I'm stumped on. This site has some info but I need some expert advice :-) http://www2.izook.com/clutch-cable/

Sometimes when pressing the clutch in I cant get into any gears, almost like I haven't pressed the clutch in far enough. I've tried adjusting the cable underneath to taken up any slack in the cable, but this hasn't worked.

The long arm that the cable attaches to on the gearbox has some play in it and I think where this connects inside the gearbox/clutch housing is where the problem is. Unfortunately I don't know the names of these components (which is probably preventing me from googling the info myself). The next photo the guy is holding an arm that goes to the gear. This arm has a bit of play, I am unable to release this arm from the shaft that goes inside the gearbox, I have loosened the bolts but it won't budge. Should this arm be vertical when the clutch is not pressed to the floor?


Another thing I have tested which might help diagnose where the fault is. I put the transfer box in neutral, gear in 1st, and using my hand spin the propshaft that goes to the gear box whilst the clutch pedal is pressed. Spinning the prop shaft it spins freely but then during it's rotation it gets stiff at roughly the same point in the rotation. This happens in any gear whilst the clutch pedal is pressed all the way down. We have tried adjusting the cable so that we can disengage the clutch more but it makes no difference which is why I think something is up inside the clutch housing.

Any ideas would be greatly appreciated. And keep in mind I'm not a mechanic.. ;-)

Thanks in advance

Clutch release bearing could have failed, only way to find out is to drop the gear box. Its suprisingly simple don't worry, can't find the walk through right now though so just search on this forum and you will find other people that have asked how.

Basically from the inside remove the 4 screws holding in the gator, should be 3 holding the gear lever in.

Underneath disconnect the clutch cable, remove the short prop, unbolt the 4 bolts holding the gearbox to the engine block, then the little bracket from the gear box to one of the cross members, reversing switch, then lift the whole thing out, they're not that heavy.

Should be able to see whats going on at that point.