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CLUTCH
SECTION
CL
CL
CONTENTS
PRECAUTIONS AND PREPARATION..........................
2
Precautions ................................................................ 2
Preparation ................................................................ 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING
................................................... 3
NVH Troubleshooting Chart....................................... 3
CLUTCH SYSTEM.........................................................
4
INSPECTION AND ADJUSTMENT
............................... 5
Inspecting and Adjusting Clutch Pedal...................... 5
Bleeding Procedure ................................................... 7
HYDRAULIC CLUTCH CONTROL
............................... 8
Clutch Master Cylinder .............................................. 8
Clutch Operating Cylinder ......................................... 9
Clutch Damper......................................................... 10
CLUTCH RELEASE MECHANISM
..............................11
CLUTCH DISC AND CLUTCH COVER
...................... 13
Clutch Disc............................................................... 13
Clutch Cover and Flywheel ..................................... 14
SERVICE DATA AND SPECIFICATIONS (SDS)
........ 15
General Specifications............................................. 15
Inspection and Adjustment ...................................... 16
PRECAUTIONS AND PREPARATION
Precautions
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GG94310000
Recommended fluid is brake fluid “DOT 4”.
Do not 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.
SBR820B
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do
not use compressed air.
Preparation
SPECIAL SERVICE TOOLS
Tool number
Tool name
GG94310000
Flare nut torque wrench
Description
Removing and installing clutch piping
NT406
a: 10 mm (0.39 in)
KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar
Installing clutch cover and clutch disc
a: 15.9 mm (0.626 in) dia.
NT645
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)
ST20050240
Diaphragm spring
adjusting wrench
Adjusting unevenness of diaphragm spring
of clutch cover
NT404
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
COMMERCIAL SERVICE TOOLS
Tool name
Equivalent to
GG94310000
1
Flare nut crows foot
2
Torque wrench
Description
Removing and installing clutch piping
NT360
a: 10 mm (0.39 in)
CL-2
Use the chart below to help you to find the cause of the symptom. The numbers indicate the order of
inspection.
Check each part in order. If necessary, repair or replace these parts.
Symptom
SUSPECTED PARTS
(Possible cause)
Reference page
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Clutch does not disengage
1
2
3
Clutch slips
1
Clutch noisy
Clutch pedal spongy
1
2
Clutch grabs/chatters
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
1
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
2
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
2
CL-5
CL-7
CL-8
CL-9
Refer to EM section
CL-11
CL-13
CL-13
CL-13
CL-13
CL-13
CL-13
CL-13
CL-13
CL-14
CL-14
CL-14
CL-14
NVH Troubleshooting Chart
CL-3
2
4
1
5
5
5
5
5
5
3
6
6
4
5
7
2
2
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
2
2
2
DIAPHRAGM SPRING ( Out of tip alignment)
CLUTCH COVER (Distortion)
FLYWHEEL (Discoloration)
CLUTCH SYSTEM
YCL007
CL-4
INSPECTION AND ADJUSTMENT
Inspecting and Adjusting Clutch Pedal
Pedal bracket
Inspect and adjust clutch pedal stroke.
Pedal stroke “S”:
Refer to SDS, CL-16.
Pedal stopper
bolt
Pedal pad
NCL057
B Pedal fully
depressed position
Master cylinder
push rod
Pedal bracket
A Pedal fully up
position
Pedal stopper
bolt
NCL058
CL-5

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