Clutch Pedal Adjustment

PROCEDURE

1. Measure the distance from the front surface of the pedal to the floor mat. Press the clutch pedal by hand until resistance is felt, and measure the free play.

Clutch pedal free play: 1–3 mm

2. If the clutch pedal free play is not within specification, adjust it as follows:

– Loosen the lock nut, turn the bolt to adjust the clutch pedal free play, then tighten the lock nut;

After adjustment, tighten the bolt until it contacts the pedal stopper, then tighten the lock nut.

– Turn the pushrod until the specified free play is obtained, then tighten the lock nut.

When adjusting the pedal height or free play, be careful not to move the pushrod toward the clutch master cylinder.

3. After completing the adjustments, check that the distance from the clutch pedal to the floor with the pedal depressed is within specification.

Clutch pedal free play (A): 1–3 mm

Distance from clutch pedal to floor with pedal depressed (B): 90 mm

4. If the pedal height and free play cannot be adjusted, there may be air in the clutch hydraulic system or the clutch master cylinder may be faulty. In this case, bleed the air from the system, or disassemble and inspect the clutch master cylinder.

CLUTCH HYDRAULIC SYSTEM BLEEDING

Any hydraulic system operates normally when air has been removed from it.

During bleeding, add only clean fluid recommended by the manufacturer.

The fluid used in the hydraulic system dissolves paint and plastic. If fluid gets on the vehicle paint, wash it off immediately with plenty of water.

PROCEDURE

1. Loosen the bleeder screw and connect a hose to it. Place the other end of the hose in a glass container of sufficient capacity.
2. Slowly depress the clutch pedal.
3. With the clutch pedal depressed, loosen the bleeder screw and release air from the hydraulic system. Tighten the bleeder screw and release the clutch pedal.
4. Repeat the operation until brake fluid flows out without air bubbles.

Rapidly pressing the clutch pedal repeatedly in the B–C range may cause the pushrod to come out of the clutch master cylinder body during bleeding. Depress the clutch pedal only after it has returned to the top position (A).

CLUTCH DISC AND PRESSURE PLATE

Clutch

1 – clutch release fork;
2 – clutch release bearing;
3 – bolt, 15–22 N·m;
4 – pressure plate;
5 – clutch disc.

PROCEDURE

1. Drain the oil from the transmission and the brake fluid from the clutch hydraulic system.
2. Remove the transmission.
3. Install clutch alignment arbor 09411-11000 for centering the clutch disc, which in this case prevents the clutch disc from falling.
4. Gradually loosen the clutch assembly bolts in a diagonal sequence, turning each bolt ? turn until the diaphragm spring force is released and the bolts can be removed by hand. Remove the clutch cover assembly with the pressure plate and the clutch disc.

Do not clean the clutch disc or the clutch release bearing with solvent.

It is recommended to remove the flywheel and check the rear crankshaft oil seal for leaks. If necessary, replace the oil seal.