2005 SUZUKI MARUTI clutch

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WARRANTY POLICY
2-1WARRANTY POLICYMaruti Suzuki India Limited (hereinafter called "Maruti Suzuki"),
warrants that each new Maruti Suzuki vehicle distributed in India
by Maruti Suzuki and sold by an authorised Maruti Suzuki dealer
will be free, under normal use and service, from any defects in
material and workmanship at the time of manufacture SUBJECT
TO THE FOLLOWING TERMS AND CONDITIONS:
(1) Qualification:
To qualify for this warranty:
(a) The Maruti Suzuki vehicle must be delivered by Maruti
Suzuki authorised dealer and set-up, serviced by Maruti
Suzuki authorised dealer/service station.
(b) The warranty registration card in respect of each vehicle
must be completed by the dealer at the time of delivery
of the vehicle and dealer should retain the same.
(2) Term:
The term of the warranty shall be twenty four (24) months
or 40,000 kilometers (whichever occurs first) from the date
of delivery to the first owner.
(3) Maruti Suzuki's Warranty Obligation:
If any defect(s) should be found in a Maruti Suzuki vehicle
within the term stipulated above, Maruti Suzuki's only obligation
is to repair or replace at its sole discretion any part shown
to be defec-tive, with a new part or the equivalent at no cost
to the owner for parts or labour, when Maruti Suzuki
acknowledges that such a defect is attributable to faulty
material or workmanship at the time of manufacture. The
owner is responsible for any repair or replacements which are
not covered by this warranty.(4) Limitation:
This warranty shall not apply to:
(1) Normal maintenance service required other than the three
free services, including without limitation, oil and fluid
changes, headlight aiming, fastener retightening, wheel bal-
ancing, wheel alignment and tyre rotation, cleaning of injec-
tors, adjustments of carburettor, ignition timing, clutch and
valve clearance.
(2) The replacement of normal wear parts including without
limitation, bulbs, tyres and tubes, spark plugs, belts, hoses,
filters, wiper blades, brushes, contact points, fuses, clutch
disc, brake shoes, brake pads, cable and all rubber parts
(except oil seal and glass run).
(3) Any vehicle which has been used for competition or racing.
(4) Any repairs or replacement required as a result of
accidents or collision.
(5) Any defects caused by misuse, negligence, abnormal use
or insufficient care.
(6) Any vehicle which has been modified or altered, including
without limitation, the installation of performance accessories.
(7) Any vehicle on which parts or accessories not approved
by Maruti Suzuki have been used.
(8) Any vehicle which has not been operated in accordance
with the operating instructions in the Maruti Suzuki Owner’s
Manual.
(9) Any vehicle which has not received, during the warranty
term, the service inspections prescribed in the Maruti
Suzuki Owner’s Manual.
(10) Any vehicle which has been assembled, disassembled,
adjusted or repaired by other than an Maruti Suzuki
authorised dealer/service station.

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OPERATING YOUR VEHICLE
5-4
Parking Brake Lever
83K-03-006
w ww w
w WARNING
Never drive your vehicle with the
parking brake on: rear brake effec-
tiveness can be reduced from over-
heating, brake life may be
shortened, or permanent brake
damage may result.
If the parking brake does not hold
the vehicle securely or does not (1) To apply
(2) To release
(3) To release
The parking brake lever is located between
the seats. To apply the parking brake, hold
the brake pedal down and pull the parking
brake lever all the way up. To release the
parking brake, hold the brake pedal down,
pull up slightly on the parking brake lever,
push the button on the end of the lever with
your thumb, and lower the lever to its origi-
nal position.
V VV V
V
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w WARNING
V VV V
V
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w WARNING
Always apply the parking brake fully
before leaving your vehicle or it may
move, causing injury or damage.
When parking, make sure the gearshift
lever is in 1st gear or “R” (Reverse).
Remember, even though the
transmission is in gear, you must
apply the parking brake fully.fully release, have your vehicle
inspected immediately by MARUTI
SUZUKI authorized dealer.
w ww w
w WARNING
When parking the vehicle on a slope,
the following procedure should be
used:
1) Apply the parking brake.
2) Shift the transmission into reverse
or first gear.
3) With the engine off, get out of the
vehicle and put chocks under the
wheels.
4) Release the parking brake.
When you return to your vehicle,
you must remember to first apply
the parking brake, then remove the
wheel chocks.
EXAMPLE
PedalManual transaxle
83K-03-007
EXAMPLE
Automatic transaxle
83K-03-008
EXAMPLE
Clutch Pedal (1)
(For manual transaxle)The clutch pedal is used to disengage the
drive to the wheels when starting the
engine, stopping, or shifting the gearshift
lever. Depressing the pedal disengages the
clutch.
w ww w
w WARNING
Do not drive with your foot resting on
the clutch pedal. It could result in
excessive clutch wear, clutch damage,
or unexpected loss of engine braking.

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OPERATING YOUR VEHICLE
5-5 Brake Pedal (2)Your SUZUKI vehicle is equipped with front
disc brakes and rear drum brakes.
Depressing the brake pedal applies both
sets of brakes.
You may hear occasional brake squeal
when you apply the brakes. This is a
normal condition caused by environmental
factors such as cold, wet, snow, etc.
w ww w
w WARNING
If brake squeal is excessive and
occurs each time the brakes are
applied, you should have the brakes
checked by your SUZUKI dealer.
w ww w
w WARNING
Do not “ride” the brakes by applying
them continuously or resting your foot
on the pedal. This will result in
overheating of the brakes which could
cause unpredictable braking action,
longer stopping distances, or
permanent brake damage.Accelerator Pedal (3)This pedal controls the speed of the engine.
Depressing the accelerator pedal increases
power output and speed.
Starting the EngineBefore Starting the Engine
83K-03-008A
1) Make sure the parking brake is set fully.
2) Manual transaxle – Shift into “N”
(Neutral) and depress the clutch pedal
all the way to the floor. Hold the clutch
pedal while starting the engine.
Automatic transaxle – If the gearshift
lever is not in “P” (Park) position, shift
into “P” (Park). (if you need to re-start
the engine while the vehicle is moving,
shift into “N”.)NOTE:
Automatic transaxle vehicles have a starter
interlock device which is designed to keep
the starter from operating if the transaxle
is in any of the drive positions.
Make sure that the parking brake is set
fully and the transaxle is in Neutral
before attempting to start the engine.
w ww w
w WARNING
Starting a Cold and Warm EngineWith your foot off the accelerator pedal,
crank the engine by turning the ignition key
to “START”. Release the key when the
engine starts.
NOTICE
Stop turning the starter immediately
after the engine has started or the
starter system can be damaged.
Do not crank the engine for more
than 15 seconds at a time. If the
engine doesn’t start on the first try,
wait about 15 seconds before trying
again.
If the engine does not start after 15
seconds of cranking, wait about 15 seconds,
then press down the accelerator pedal to
1/3 of its travel and try cranking the engine
again. Release the key and accelerator
pedal when the engine starts.
If the engine still does not start, try holding
the accelerator pedal all the way to the floor
while cranking. This should clear the engine
if it is flooded.

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OPERATING YOUR VEHICLE
5-6
CAUTION
Stop turning the starter immediately
after the engine has started or the
starter system can be damaged.
Do not crank the engine for more
than 15 seconds at a time. If the
engine doesn’t start on the first try,
wait about 15 seconds before trying
again.
Warm engine
Crank the engine by turning the ignition key
to “START”. Release the key when the
engine starts.
CAUTION
When stopping the engine with tur-
bocharger:Downshifting Km/h
2nd to 1st 20
3rd to 2nd 54
4th to 3rd 80
5th to 4th 112
83K-03-009
Using the Transmission
Starting off
To start off, push in the clutch pedal and
change into 1st gear. After releasing the
parking brake, gradually release the clutch.
When you hear a change in the engine’s
sound, slowly press the accelerator while
continuing to gradually release the clutch.
Gear Changing
All forward gears are synchronized, which
provides for quiet, and easy changing.
Always push in the clutch pedal fully before
changing gears.Downshifting maximum allowable
speedsPetrol Engine
Downshifting Km/h
2nd to 1st 24
3rd to 2nd 60
4th to 3rd 92
5th to 4th 125
If the engine still does not start, try holding
the accelerator pedal all the way to the floor
while cranking. This should clear the engine
if it is flooded.(For Diesel Engine Model)Cold engine
Turn the ignition switch to the “ON” position
and wait until the glow plug indicator goes
out if it comes on. Crank the engine by
turning the ignition key to “START”. Release
the key when the engine starts. When stopping the engine after
climbing or high speed driving, let
the engine idle for about one minute
or more (if it is not prohibited) to
cool down the turbocharger and
engine oil. This is to prevent the
engine oil from over-deteriorating.
Deteriorated engine oil will damage
the bearings of the turbocharger.
Restarting diesel engine after fuel-
empty stop
The engine stops and the malfunction indi-
cator light comes on if the engine feels fuel
emptiness. To restart the engine, stop the
vehicles, hold the ignition key in “ON” posi-
tion for 5–10 seconds to feed fuel, then
perform above engine starting procedure.
Have the indicator light turned off by your
MARUTI SUZUKI dealer.
Diesel Engine
V VV V
V
CAUTION
V VV V
V

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OPERATING YOUR VEHICLE
5-7Petrol
83K-03-010
Diesel
83K-03-011
CAUTION
When downshifting to a lower gear,
make sure not to operate with the
speed faster than the maximum
allowable speeds for the next lower
gear, or severe engine damage can
result.
Keep the engine speed so it does not get
into the red zone of tachometer.
w ww w
w WARNINGCAUTION
To help avoid clutch damage, do not
use the clutch pedal as a footrest
while driving or use the clutch to
keep the vehicle stationary on a
slope. Depress the clutch fully when
shifting.
When shifting or starting off, do not
race the engine. Racing the engine
can shorten engine life and affect
smooth operation.
83K-03-011A
4-Speed Automatic Transaxle
Gearshift lever
83K-03-011B
w ww w
w WARNING
Always depress the brake pedal before
shifting from “P” (Park) (or “N”
(Neutral) if the vehicle is stationary) to
a forward or reverse gear, to help
prevent the vehicle from moving
unexpectedly when you shift.
Reduce your speed and downshift
to a lower gear before going down
a long or steep hill. A lower gear
will allow the engine to provide
braking. Avoid riding the brakes or
they may overheat, resulting in
brake failure.
When driving on slippery roads, be
sure to slow down before changing
down. Excessive and or sudden
changes in engine speed may cause
loss of traction, which could cause
you to lose control.
Make sure that the vehicle is com-
pletely stationary before you shift
into reverse.
NOTE:
You may not accelerate to the maximum
allowable speed because of the driving sit-
uation and/or the vehicle condition.

Downloaded from www.Manualslib.com manuals search engine 8983KINSPECTION AND MAINTENANCE
Maintenance Schedule ....................................................................................................... 9-1
Drive Belt ............................................................................................................................. 9-6
Engine Oil and Filter......................................................................................................... 9-6
Engine Coolant.................................................................................................................... 9-9
Air Cleaner ......................................................................................................................... 9-11
Spark Plugs....................................................................................................................... 9-11
Gear Oil.............................................................................................................................. 9-13
Clutch Pedal...................................................................................................................... 9-14
Fuel Filter (Diesel engine) .............................................................................................. 9-14
Brakes ................................................................................................................................. 9-15
Steering.............................................................................................................................. 9-16
Tyres ................................................................................................................................... 9-17
Battery................................................................................................................................ 9-19
Fuses ................................................................................................................................... 9-20
Bulb Replacement............................................................................................................. 9-23
Wiper Blades..................................................................................................................... 9-26
Windshield Washer Fluid................................................................................................9-28
Air Conditioning System.................................................................................................9-29
INSPECTION AND MAINTENANCE

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FREE INSPECTION PERIODIC MAINTENANCE AT COST
Interval: This interval should be judged by odometer km (x1000) 1 5 10 20 30 40 50 60 70 80
reading or months, whichever comes first.months 1 6 12 24 36 48 60 72 84 96
CLUTCH AND TRANSMISSION
4-1. Clutch Pedal (Play) PetrolIIIIIIIIII
4-2.Clutch Fluid (Level, Leakage) Diesel I I I R I R I R I R
4-3. Clutch Slipping (Dragging or Excess Damage)IIIIIIIIII
4-4.
Manual Transmission/Transfer or Differential Oil (Level, Leakage)
I I IRIRIRIR
4.5. Automatic transmission Fluid (Level, Leakage) Replace at 1,65,000 KM or 11 years whichever comes first
4.6. Hose, Automatic transmission fluidIIIIIIIIII
DRIVE SHAFT
5-1. Drive shaft boot (boot damage) -IIIIIIIII
BRAKE
6-1. Brake Fluid (Level, Leakage) I I I R I R I R I R
6-2.Brake Pedal (pedal - wall clearance)IIIIIIIIII
6-3.Parking brake lever and cable (Play, damage)IIIIIIIIII
6-4.Brake disc and pad (Wear) -IIIIIIIII
6-5.Brake drum and shoes (Wear) - -IIIIIIII
6-6. Master cylinder/wheel cylinder/caliper (Oil leakage, boot cut)
IIIIIRIIIR
(replace piston and boot kits)
6-7.Brake hoses and pipes (Leakage, damage)IIIIIIIIII
WHEEL
7-1.Tyres (air pressure, abnormal wear, crack and rotation) I I&O I&O I&O I&O I&O I&O I&O I&O I&O
7-2. Wheels (Damage)IIIIIIIIII
7-3.Front/Rear wheel bearing (Loose, damage)IIIIIIIIII
FRONT / REAR SUSPENSION
8-1.Suspension strut (Oil leakage, damage)IIIIIIIIII
8-2. Suspension arms / Knuckle support (Loose, damage) -IIIIIIIII
8-3.Rear spring (Damage)IIIIIIIIII
8-4.Shock absorbers (Oil leakage, damage)IIIIIIIIII
8-5.All bolts and nuts (Loose) -TTTTTTTTT
8-6. Suspension arms and torsion rods -IIIIIIIII
INSPECTION AND MAINTENANCE
9-4

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INSPECTION AND MAINTENANCE
9-14 Gear Oil Change
Since special procedures, materials and
tools are required, it is recommended that
you trust this job to your MARUTI SUZUKI
authorized dealer.Clutch PedalCable control clutch (For Petrol)
83K-07-028
Clutch pedal play “d”:
Petrol Engine
11 - 13 mm (0.4 - 0.5 in.)
Diesel Engine
5 - 7 mm (0.2 - 0.27 in.)
Measure the clutch pedal play by moving
the clutch pedal with your hand and mea-
suring the distance it moves until you feel
slight resistance. The play in the clutchpedal should be between the specified val-
ues. If the play is more or less than the
above, or clutch dragging is felt with the
pedal fully depressed, have the clutch
inspected by your MARUTI SUZUKI dealer.
Fluid Control Clutch (For Diesel)Check the clutch pedal for smooth operation
and brake fluid level from time to time.
If clutch dragging is felt with the pedal fully
depressed, have the clutch inspected by your
MARUTI SUZUKI dealer. If the brake fluid
level is near the “MIN” line, fill it up to the
“MAX” line with Maruti Genuine brake fluid.
83K-07-029
EXAMPLE
EXAMPLE
Automatic Transaxle (AT)
FluidSpecified Fluid
Use an automatic transaxle fluid:
SUZUKI ATF 3317 or Mobil ATF 3309
Fluid Level Check
NOTICE
Driving with too much or too little
fluid can damage the transaxle.
You must check the fluid level with the
automatic transaxle fluid at normal operating
temperature.
To check the fluid level:
1) To warm up the transaxle fluid, drive the
vehicle for 20 more minutes.
NOTICE
Be sure to use the specified automatic
transaxle fluid. Using automatic
transaxle fluid other than SUZUKI ATF
3317 or Mobil ATF 3309 may damage
the automatic transaxle of your
vehicle.NOTE:
Do not check the fluid level if you have just
driven the vehicle for a long time at high
speed, if you have driven in city traffic in