(09-11-2021, 03:12 PM)maint Wrote: Got time for another clutch question?
After a extensive test of my patience and back I have everything back together. Stop and switch(s) adjusted, cable back on the hook.
Final adjustment would be at the bell housing.
The threaded part of the cable [kind with the rubber, not two lock nuts] is too short as it is. (wrong cable)
I run out of slack at the clutch lever about 1/2 way through the radius-ed end nut .  RUBBER cable mount fully seated?, and no collision damage on the frame mount?
what I do, is  mount the new cable at both ends routed correctly
then install the top shackle,  up top and at the use a bungee cord to hold tension the bottom doing the above, small easy to pull bungee,
now at the bottom while holded the cable in hand release  the bungee so  as that top does not fall off, and attached the bottom end, now.



I found the little mark on the clutch shaft end and it is lined up with the one on the arm. (all 2 splines have marks)
Square hole in the clutch pedal arm is in same location, the weld on the clutch shaft was starting to crack but had not gone through.
Any suggestions?
for 2 short? the cable?  (routed wrong or wrong cable.)

(09-12-2021, 02:40 AM)maint Wrote: Early this morning I took the cable off and reinstalled it. I did use a bungee to ensure the shackle didn't flop off. The shackle is seated on the arm correctly and seated on rubber by bell housing. Can tell by the threaded end it was never cut. 
I blew the pic up and found the little mark on the arm and it is beside the one on the clutch shaft. The clutch seemed good and no hint of a problem until the switch pedal arm cracked enough to not hit the pedal position switch. Pedal weld to the shaft was starting to crack but had not let go yet and the cable arm square is in the same spot it was (saved most of the square hole and only had to file the welds). The stop bracket being jerry-rigged would have no effect on this
I think that only leaves the cable but it worked before and I did check the adjustment when I got the car not too many miles back. . Suzuki has a parts warehouse in Canada but the cable is back ordered and they are trying to find an ETA for me.

Suzuki's revised number is good for all Trackers/ Sidekicks and X90 (according to most, but not all, sites I checked) When I ordered the cable the parts guy at the local Suzuki warranty dealer said he sells 3 or 4 a month so they will continue to stock them. I 'm guessing they must be the same as he also says he never sees an X90 anymore. This one is 8.5 inches from rubber flange (as per your drawing on free play) before installed but only 7.5" when installed on arm.

(09-12-2021, 03:28 AM)fixkick Wrote: oops/.
are you missing a key part seen as ID #18

(09-12-2021, 04:42 AM)maint Wrote:

(09-12-2021, 03:28 AM)fixkick Wrote: oops/.
are you missing a key part seen as ID #18

The pivot is there. Just looked at pedal arm again and, with clutch pedal .2" above brake pedal, there is 1- 1.5 " of cable between the arm and the metal sheath the cable comes out of. I can push the clutch pedal to floor, releasing clutch, with hands from under dash position so is not too hard. Triple checked everything I can think of and all looks good until I try to adjust nut #19 further on. Cable worked for me before BUT obviously someone had issues before I bought it. It is possible the pedal was set higher originally as I don't remember checking it when I first checked for slack. Had just bought it and didn't have a manual or procedure, just ensured there was some slack in cable.  I am going to need it in a week for a few days so I'm thinking of moving it on the spline at the clutch release lever one tooth and correct it when a new cable comes. I guess it is possible that cable is now catching inside, under tension, but it sure doesn't feel like it.
Is there a burning reason to NOT adjust at clutch arm?

(09-14-2021, 03:07 PM)maint Wrote: It's not getting easier.
Tried moving the release lever on the splines and got lots of thread showing through, possibly too much. Clutch did not disengage so I moved it back to the original marks. Very little slack at lever, guesstimate at 1mm and brake pedal free travel down to about 1/2". Started the car with 4 wheels in the air and the clutch is dragging? 
Brake off, clutch in,= wheels spin.
Brake on, clutch in= wheels stop and motor doesn't notice but going into reverse a bit reluctant. So clutch has a little drag.
Tried to get a bit more clutch pedal travel and can only gain a very little before the pedal stop bracket contacts the metal bracing. As the bracket was smashed down before this wasn't an issue. Was that why it was smashed?
Not going to do anything until the new cable comes but i am getting the 1" or so travel at the lever end (#18) with this one so it is pointing to a bigger issue.