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Gen 4 Clutch - Heavy Duty - Any suggestions?

  • DrRobin
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01 Oct 2025 08:40 #262147 by DrRobin
I had a funny thing with my clutch a year ago, the pedal kind of jumped when disengaging.  By the time it was booked in to have it checked, it had stopped doing it and the Suzuki garage had the car for a full day in the workshop and out on several test drives but couldn’t find anything wrong.

Fast forward to last weekend and a lot of off-roading and steep hills on tarmac and on Saturday afternoon I had judder when the clutch just bit in first gear about 3 times, especially when slipping the clutch.  After that I was careful to try to minimise clutch slip and the next day no judder.

My Gen 4 has done 33,000 miles.

It all looks like a worn clutch plate, which isn’t covered on the warranty.  It might be contamination (water or oil) or the flywheel, this might be covered.

So here is the dilemma, if it’s clutch I want to fit an aftermarket heavy duty clutch, but not sure which one and my guess would be that the Suzuki garage won’t fit anything other than standard parts.

So do I get the work done at my local friendly/family garage and get a better clutch, taking a chance on some more serious or do I book it in at the Suzuki garage?

Has anyone a recommendation for an updated heavy duty clutch?

Ta 

2020 blue SZ5 (one of the last to be registered in the UK)
Ex 2011 Blue Jimny SZ4
Northumberland Jimny Blog

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01 Oct 2025 09:39 #262148 by mlines
Robin

I took a look at the service manual and there are no adjustment points, although there are greasing points on the pedal and the actuator.

For clutches, I do not have any experience of the gen4

I know some people rate LOF clutches and I can see this one listed

lofclutches.com/shop/clutches/suzuki/pow...-2018-on-clutch-kit/

The Suzuki Part number is: 22400-78R00  and they occasionally do "offers" on the clutch kit

If you google that part number you can see a number of clutches listed

Martin

Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses
The following user(s) said Thank You: 300bhpton, Filipao

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01 Oct 2025 21:10 #262149 by Hughes
I have an HD Exedy in my gen 3 and it seems to go well with no issues. I haven't heard of others having issues with them either. 

It "bites" more aggressively than the stock clutch, and as the friction material and heavier springs are designed to slip less, starting on a steep tarmac hill without stalling does require commitment and many revs. 

Just bear in mind that an HD clutch will burn up just as fast (sometimes even faster) if you slip it...

The pedal sticking is probably more of a release bearing issue. Someone with experience with the gen4 could say whether the hydraulic clutch system on the gen4 can cause that. 
 

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02 Oct 2025 11:50 #262151 by Motacilla
Slight occasional judder is normal. The clutch has not failed, is not contaminated, and is not significantly worn.

The Jimny clutch is tiny, but so are the loads on it. Putting in a disk with different lining or -- more to your situation -- a pressure plate with heavier springs will give no real benefit, and as @Hughes points out some drawbacks in daily use.

When the clutch actually fails or becomes too worn for service, you will know it, and it won't be an intermittent thing.

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06 Oct 2025 08:42 - 06 Oct 2025 08:46 #262180 by yakuza
Gen3 and Gen4 clutches are the same?
(Edit -they do not look the same so I am guessing no.)

I am currently running a Samurai Centerforce Dual Friction clutch with the high rev weights removed on my Gen3.
trailtough.com/product/centerforce-dual-friction-clutch-kit/

Pedal feel and all is very nice, no judder, no nothing.

It does not smell even with a M16, 235's, original gears (no geared down transfer now) and, pulling a trailer.
Should have inspected it while my gearbox was out a few weeks back but did not bother.

Norway 2005 Jimny M16A VVT, 235 Cooper Disco, 2" Trailmaster, ARB rear lck.
Last edit: 06 Oct 2025 08:46 by yakuza. Reason: added info

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  • Lambert
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06 Oct 2025 09:36 #262182 by Lambert
My old man managed to smoke the clutch in bellerophon with a full trailer on a road junction. I put it down to willfully wanting to make a point but this does seem to suggest they might not be the strongest thing. That said though I still think that the tyres are too tall for serious work.

Temeraire (2018 quasar grey automatic)
One of the last 200ish of the gen3s, probably.
Bellerophon (2024 grello van daily
ADOS Attention Deficit Ooooh Shiny!

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