| CLUTCH wn CL CONTENTSL ees4s10000 PRECAUTIONS Precautions @ Recommended fluid Is brake fluid “DOT 3”. Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas, When removing and installing clutch piping, use Tool. Use new brake fluid to clean or wash all parts of master cylinder, operating cylinder and clutch damper. @ Never use mineral oils such as gasoline or kerosene, It will ruin the rubber parts of the hydraulic system. WARNING: After cleaning the clutch dise, wipe it not use compressed ai with a dust collector. Do CL-2PREPARATION SPECIAL SERVICE TOOLS *: Special too! or commercial equivalent '$T20050100 = > Inspecting diaphragm spring of clutch mere = os Fiore nut torque wrench —=s Removing and installing each clutch piping 20600000" («V30100100) Cluteh aligning bar s720050240" Diaphragm spring adjusting wrench Installing clutch cover and clutch dise ‘Adjusting unevenness of diaphragm spring cay of euteh cover COMMERCIAL SERVICE TOOL Description Installing clutch cover Wire: 3.210.126) dia, Lost: nm in cL-3CLUTCH SYSTEM Ale beeler tren Den (8-1.1,58-80) /~ clutch aise } Release bearing =O stearate —/ (3.1-41,22-30) L. pirbieder sew 7 EBC: Apply ithium-daied geae including molyodenum dislphide (07-09,51-6) Neo tg, Ft) CL-4INSPECTION AND ADJUSTMENT Adjusting Clutch Pedal 1. Adjust pedal height with pedal stopper. Pedal height "H*": 202 - 212 mm (7.95 - 8.35 in) +: Measured from surface of melt sheet to pedal pad 2. Adjust pedal free play with master cylinder push rod or | Clutch booster input rod. Then tighten lock nut fed! tonper Pedal free play “A: Gite 1.0 - 3.0 mm (0.099 - 0.118 in) 118-22, | Pedal free play means the following total measured at posi- a tion of pedal pad: © Play due to levis pin and clevis pin hole in clutch pedal. i Dash lower pact Mat shee. FL: nem tigen. tim) scsze Bleeding Procedure Bleed air according to the following procedure. Clutch operating cylinder — Clutch piping connector © Carefully monitor fluld level et master cylinder during bleeding operation. Top up reservoir tank with recommended brake fluid. Connect a transparent vinyl tube to air bleeder valve. Fully depress clutch pedal several times. With clutch pedal depressed, open bleeder valve to release air. Close bleeder valve Repeat steps 3 through 5 above until clear brake fluid comes out of air bleeder valve Sei “Goren piping connector scLae2 CL-5HYDRAULIC CLUTCH CONTROL Clutch Master Cylinder Models without clutch booster | Piston cup BEA® Manos: CL-6HYDRAULIC CLUTCH CONTROL ‘Models with clutch booster Push rod Stovper Stopper ring && becom er seek O)s-1208-12,58-87 Piston sembly Clutch Master Cylinder (Cont'd) >> | Grxr | 1028-04, | | Sorin seat euinsring Cy 18-29) - cya bey gr | Mh s-12108-12,5: on\ TA: Wem thom, 00) DISASSEMBLY AND ASSEMBLY © Push piston in cylinder body with suitable tool when re- moving and installing valve stopper. © Align groove of piston assembly and valve stopper portion when installing valve stopper. © Check direction of piston caps. INSPECTION © Check cylinder and piston rubbing surface for uneven wear, rust or damage. Replace if necessary. © Check piston with piston cup for wear or damage. Replace if necessary. 1 © Check return spring for wear or damage. Replace if neces- sary. © Check reservoir for deformation or damage. Replace if necessary. @ Check dust cover for cracks, deformation or damage. Replace if necessary, CL-7HYDRAULIC CLUTCH CONTROL Clutch Operating Cylinder 17-9 Nm (07-0.9k9m,5.1-6.5 te) / ae? HEEB Rubbing wrtace FEAL n= Apply rubber pre. INSPECTION ‘© Check rubbing surface of cylinder for wear, rust or damage. Replace i necessary ‘© Check piston with piston cup for wear or damage. Replace if necessary. © Check dust cover for cracks, deformation or damage. Replace if necessary. Clutch Booster a Nem tigen te)HYDRAULIC CLUTCH CONTROL | Clutch Booster (Cont'd) INSPECTION Hoses and connectors ‘Check condition of vacuum hoses and connections. ‘® Check vacuum hoses and check valve for air tightness. Check valve @ Install check valve properly paying attention to its direction, | | | pum sie Soe © When pressure is applied to the clutch booster side of check valve and valve does not open, replace check valve with @ new one, =e Vacuum pump Clutch booster ae ide | ADEN, Output rod length: Length “A” 1.30 - 1.55 mm (0.0512 - 0.0610 in) scu136 Ce H amount of adjustment required exceeds 0.5 mm (0.020 in) reaction disc may have either been dislocated or fallen off, Replace clutch booster assembly. ssi]HYDRAULIC CLUTCH CONTROL Clutch Booster (Cont'd) Input rod length: Length 130 mm (5.12 in) CL-10 =| CLUTCH RELEASE MECHANISM Pelee soe =o fete vearng orcs 9 CBG Cates ts sein ne wien — ce < . EL: sot itimband gee eng or ae \ i 2 geen ‘eruine pare KP610-00260) or \“eaq re Sauivalan. REMOVAL AND INSTALLATION © Install retainer spring and holder spring, © Remove release bearing. ‘© Install release bearing with suitable drift. | one CL-11CLUTCH RELEASE MECHANISM INSPECTION © Check release bearing to see that it rolls freely and is free from noise, crack, pitting or wear. Replace if necessary. © Check release sleeve and withdrawal lever rubbing surface for wear, rust or damage. Replace if necessary, LUBRICATION © Apply recommended grease to contact surface and rubbing surface. ‘Too much lubricant might cause clutch disc facing damage.ES CLUTCH DISC AND CLUTCH COVER 3D not lean insolent. When instaling, be caretul that presse applied to iain drive shat doesnot adhere to cuteh die 22.29% 22-30190, 1o-22 hab) EEO: Aopy ieniumbesed gress nciding Clutch cover ‘melvodenum aiauiphde Clutch Disc INSPECTION Check clutch disc for wear of facing, Wear limit of facing surface to rivet h 0.3 mm (0.012 in) 0.3 mm (0.012 in) © Check clutch disc for backlash of spline and runout of facing Maximum backlash of spline (at outer edge of dis 4.0 mm (0.039 in) Runout limit: 1.3 mm (0.051 in) Distance of runout check point (from hub center): 109 mm (4.29 in) © Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary. unout of facing Bsckinn of spine INSTALLATION © Apply recommended grease to contact surface of spline portion ‘Too much lubricant might cause clutch disc facing damage. CL-13CLUTCH DISC AND CLUTCH COVER Usage sr2005004 e Clutch Cover and Flywheel INSPECTION © Set Tool and check height and unevenness of diaphragm spring. Diaphragm spring height “A”: 37.5 - 39.5 mm (1.476 - 1.585 in) © Set 0.1 mm (0.004 in) feeler gauges on distance piece (8720050100) when checking diaphragm spring height. © Check thrust rings for wear or damage by shaking cover assembly up and down to listen for chattering noise, or lightly hammering on rivets for a slightly cracked noise. Replace clutch cover assembly if necessary. © Check pressure plate and clutch disc contact surface for slight burns or discoloration. Repair pressure plate with ‘emery paper. © Check pressure plate and clutch disc contact surface for deformation or damage. Replace if necessary. ® Adjust unevenness of diaphragm spring with Tool Uneven limit: 0.7 mm (0.028 in) © Check flywheel and clutch disc contact surface for slight burns or discoloration. Repair flywheel with emery paper. © Check flywheel runout. Runout (Total indicator reading): Less than 0.1 mm (0.004 In) INSTALLATION © Use suitable wire when installing clutch cover.CLUTCH DISC AND CLUTCH COVER Clutch Cover and Flywheel (Cont'd) © Insert Too! into clutch disc hub when installing clutch cover and disc © Remove wire after installing clutch cover and disc.SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications CLUTCH CONTROL SYSTEM CLUTCH DISC “Type of ash convel Hyaraule Todor 2a0TBL. (mace er eee CLUTCH MASTER CYLINDER thickness Lae tebe Inner diameter ‘mm Gnd 15.7 (678) CLUTCH OPERATING CYLINDER Inner diameter mm Gin) CLUTCH BOOSTER ‘Duphragm dlemeter oom (in) Greek vale wee 79905 (3/4) Folliond te) Thcknen of die anembly With ood zr iNT 1) CLUTCH COVER ‘oder Inspection and Adjustment 27 -8.1(0303 -0319)/ 5,304 (560, 1.212) 240K 15.398 1550, 1233), cLUTCH PEDAL cturen oise roi cena al 7 oe | eee CLUTCH BOOSTER aE Te Output rod engin nut rd nat Unit: mm in) 120-188 (0512 0106101 3906.12) Unt outer edge of disc) CLUTCH COVER Units men i ‘Diaphragm spring height ‘Uneven limit of diaphragm sring tow hehe b2K0K 375-305 (1476-1588) 027 (0.026)