Kia Rio YB Quiz

Clutch System

In this manual: Clutch System
General Information — 8Maintenance — 31Engine Mechanical System — 44Engine Electrical System — 14Emission Control System — 9Engine Control System/Fuel System — 30Clutch System — 10Manual Transmission — 10Automatic Transmission — 23Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 14Brake System — 22Body (Interior and Exterior) — 115Body Electrical System — 84Heating, Ventilation, and Air Conditioning — 28
~3min read
1special tools

Specifications

Specifications

Items Specifications
Clutch Operating Method Hydraulic Type
Clutch Cover Type Diaphragm Spring Strap
Clutch Disc Type Type Single Dry Diaphragm
Facing Diameter
(Outer × Inner)		 Gasoline 1.4: Ø200 ± 1 × Ø130 +0.8 mm
(Ø7.8740 ± 0.0394 × Ø5.1181 +0.0315 in.)
Gasoline 1.0 T-GDI: Ø225 ± 1 × Ø155 +0.8 mm
(Ø8.8583 ± 0.0394 × Ø6.1024 +0.0315 in.)
Gasoline 1.25: Ø225 ± 1 × Ø130 +0.8 mm
(Ø7.4803 ± 0.0394 × Ø5.1181 +0.0315 in.)
Diesel 1.4: Ø235 ± 1 × Ø155 +0.8 mm
(Ø9.2520 ± 0.0394 × Ø6.1024 +0.0315 in.)
Clutch Disc Thickness [Free State] Gasoline 1.0 T-GDI / 1.4: Ø8.1 ± 0.3 mm (0.3189 ± 0.0118 in.)
Diesel 1.4: Ø8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)
Gasoline 1.25: Ø7.9 ± 0.3 mm (0.3110 ± 0.0118 in.)
Clutch Disc Rivet Depth 1.1 mm (0.0433 in.)

Service Standard

Item Specification
Clutch Disc Rivet Depth 0.3 mm (0.0118 in.)

Tightening torque

Item N·m kgf·m lbf·ft
Clutch Pedal Mounting Nut 16,7 - 25,5 1,7 - 2,6 12,3 - 18,8
Ignition Switch and Clutch Switch Mounting Bolt 2,0 - 3,9 0,2 - 0,4 1,4 - 2,9
Clutch release cylinder bleeder screw 6,8 - 9,8 0,7 - 1,0 5,0 - 7,2
Clutch housing mounting bolt
(Gasoline 1.0 T-GDI, 1.25, 1.4)		 14,7 - 21,6 1,5 - 2,2 10,8 - 15,9
Clutch housing mounting bolt
(Diesel 1.4)		 11,8 ~ 14,7 1,2 ~ 1,5 8,7 - 10,8
Clutch release cylinder mounting bolt 14,7 - 21,6 1,5 - 2,2 10,8 - 15,9

Lubricants

Items Specified Lubricants Quantity
Clutch Release Cylinder Assembly DOT 3 or DOT 4 brake fluid As Required
Clutch pedal shaft and bushing Chassis grease SAE J310a, NLGI No. 1
Input shaft spline CASMOLIA L9508 0.2 g
Release Bearing and Fork 0.3 - 0.5 g
Release Fork and Pivot Point 0.5 - 1.0 g
Release Cylinder and Fork 0.4 - 0.8 g
Clutch Release Bearing and Clutch Housing 0.5 - 1.0 g

Special Service Tools

Special Service Tools

Tool Name/Number Illustration Description
Clutch Disc Guide
09411-1P000
Clutch disc installation

Troubleshooting

Troubleshooting

Symptom Suspected Area Remedy
Clutch grabs / chatters Engine Mounting (Loose) Tighten the engine mount.
Clutch Disc Assembly (Excessive Runout) Inspect the clutch disc.
Clutch Disc Assembly (Oily) Inspect the clutch disc.
Clutch Disc Assembly (Worn) Replace the clutch disc.
Clutch disc torsion spring (damaged) Replace the clutch disc.
Clutch Disc Assembly (Glazed) Inspect the clutch disc.
Diaphragm Spring (Misalignment) Replace the clutch disc.
Clutch Pedal Spongy Clutch line (air in line) Perform air bleeding.
Clutch master cylinder (damaged) Replace the clutch master cylinder.
Release cylinder (damaged) Replace the clutch release cylinder.
Clutch noisy Clutch Release Bearing Assembly (Worn, Contaminated or Damaged) Repair or replace the clutch release bearing.
Clutch slips Clutch Disc Assembly (Oily) Inspect the clutch disc.
Clutch Disc Assembly (Worn) Replace the clutch disc.
Diaphragm spring (damaged) Replace the clutch disc.
Pressure Plate (Distorted) Replace the clutch disc.
Flywheel (Distorted) Replace the flywheel.
Clutch does not disengage Clutch line (air in line) Perform air bleeding.
Clutch master cylinder (damaged) Replace the clutch master cylinder.
Release cylinder (damaged) Replace the clutch release cylinder.
Clutch Disc Assembly (Out of Line) Replace the clutch disc.
Clutch Disc Assembly (Excessive Runout) Replace the clutch disc.
Clutch Disc Assembly (Broken Facing) Replace the clutch disc.
Clutch disc assembly (dirty or burnt) Repair or replace the clutch release bearing.
Clutch Disc Assembly (Oily) Inspect the clutch disc.
Clutch Disc Assembly (Lack of Spline Lubrication) Apply grease to the splines.

Test yourself

A quick Kia Rio YB quiz: every answer comes with an explanation and a link to the manual page.