CLUTCH

GENERAL ................................................................................CH - 2
SPECIFICATIONS ....................................................................CH - 6
SERVICE STANDARDS ........................................................... CH - 7
TIGHTENING TORQUE ............................................................ CH - 9
SPECIAL TOOLS .....................................................................CH-10
SERVICE PROCEDURE
Clutch Proper .....................................................................CH-11
Clutch Pedal .......................................................................CH-17
Clutch Master Cylinder ...................................................... CH-20
Clutch Booster ...................................................................CH-22
Clutch Housing Assembly ................................................CH-27
Replacement of Brake Fluid In Clutch System ............... CH-29
Bleeding of Clutch System ...............................................CH-30
TROUBLESHOOTING ............................................................. CH-32
CH-2 CLUTCH

GENERAL
The clutch system consists of clutch proper and control. The clutch proper transmits power from the engine to the trans-
mission and performs the following functions when the clutch pedal is operated.
1) Transmitting engine power smoothly to the transmission as the vehicle is started.
2) Connecting and disconnecting engine power by transmission gearshifting.

Clutch Proper

Clutch disc
Clutch release lever

Clutch release fork

Pressure Set screw

Pressure plate
spring

AC41001

The clutch consists of the clutch disc that transmits power from the engine to the transmission and the pressure plate that
presses the clutch disc tight up against the flywheel. When the clutch pedal is depressed, the clutch booster is operated
by the hydraulic pressure from the clutch master cylinder. This causes the release bearing to push the release lever via
the clutch release fork and fork shaft. The release lever, operating on a force being applied with the support lever pin as
the fulcrum, compresses the pressure spring. As a result, the pressure plate is pulled back, cutting off power from the
engine.
When the clutch pedal is released, the clutch disc is compressed against the flywheel by the pressure spring force, thus
transmitting engine power to the transmission.
GENERAL CH-3

Clutch Control

5
3

1. Clutch pedal
2. Clutch master cylinder
8 3. Fluid reservoir tank
B 4. Clutch booster
1 5. Air tank
9 6. Push rod
7. Release fork shaft
2
4 8. Clutch disc
6
9. Flywheel
7
A : To clutch booster
B : From fluid reservoir
A

CYCH003A

The clutch pedal mechanism is the pendant type. When the pedal is depressed, the push rod is forced down into the
master cylinder, causing pressurized fluid to move the clutch booster.
The clutch booster doubles the hydraulic pressure which moves the clutch release bearing, thereby operating the clutch
proper.
The clutch booster is the type which requires adjustment according to the wear condition of the clutch disc.

Clutch Master Cylinder

Nipple
25-35Nm
(2.5~3.5kgf·m) Form oil reservoir tank

Stroke : 33mm Boot

Nut

To clutch booster
Push rod
control valve Ball joint
Cylinder
Piston Retainer ring
Return spring

ECYCL01A
CH-4 CLUTCH

1. When pushing the clutch pedal down

As the push rod compresses the piston, supply valve is closed
by spring tension. Compressing the piston more activated the
clutch booster as the pressure inside the cylinder increases.

Supply valve spring

JMS41-006

2. When releasing the clutch pedal

The oil pressure in the cylinder pushes the piston so that sup-
ply valve rod moves to the valve stopper by the return spring
tension.
Then, supply valve is opened so that oil pressure in the cylin-
der is removed.

JMS41-007

Clutch Booster
The clutch booster is the device that eases the clutch operation by
using compressed air and the oil pressure generated in the master
cylinder.

1 2 3 4 5 6 7
A
8

B
9
10

15 C
14 13 12 11

1. Piston plate 8. Poppet valve 15. Push rod

2. Spring 9. Spring
3. Relay piston 10. Control chamber A : Atmosphere
4. Air chamber 11. Push rod B : Air pressure in air tank
5. Exhaust cover 12. Return spring C : Fluid pressure in clutch
6. Upper valve body 13. Hydraulic piston master cylinder
7. Spring 14. Cylinder cell
CYCH005A
GENERAL CH-5

1. Pressing pedal
To atmosphere
When the clutch pedal is pushed down, the oil pressure from the
clutch master cylinder causes the hydraulic piston and relay valve
From air tank
piston to be pushed right. Then, the relay piston opens the pop-
pet valve by pressing poppet valve spring and supplies com- B com-
pressed
pressed air from control chamber to B chamber. This pressure air
and cylinder oil pressure push the hydraulic piston.
A atmosphere
Hydraulic piston operates release lever by using push rod. When From clutch master cylinder JMS41-010
there is no air pressure, oil pressure from clutch master cylinder
acts on the hydraulic piston so that driver has hard time to oper-
ate the clutch pedal.
2. Releasing pedal
Atmosphere
When the clutch pedal is released, the oil pressure from clutch
master cylinder decreases and the poppet valve in seat blocks
the path of compressed air so that the pressure on the piston
will not activate.
A
Relay valve piston and diaphragm returns by valve spring, and
the compressed air in B chamber is discharged to the B
Clutch master cylinder
atmosphere. Power piston and oil pressure piston return to their JMS41-011

original location by return spring.

CH-6 CLUTCH

SPECIFICATIONS
Unit : mm

Item Specification
Clutch Model Push type (C12N43)
Drive type Strap drive
Clutch disc type Single dry plate
Facing O.D x I.D 430 x 250 x 5 (7 )
Pressure plate Material Non-asbestos
Type Coil spring
Clutch control Control type Hydraulic control with clutch booster installed
Clutch pedal Stroke 150
Height 158
Play 6-8
Master cylinder Diameter x stroke 20.64 x 35
Clutch Type Play adjustment type
booster Power cylinder Diameter x stroke 105 x 30
Hydraulic cylinder Diameter x stroke 19.8 x 30
Relay valve piston Diameter x stroke 16 x 3.6
Push rod Play 3-4
SERVICE STANDARDS CH-7

SERVICE STANDARDS
Unit : mm

Nominal value Remedy and

Check item Service limit
[basic diameter] Remark
Single Clutch Depth between rivet and facing surface 2.2~2.8 0.2 Thickness:
clutch disc 10.0±0.3
disc Flatness 0.3~1.2 1.2
Runout Vertical 1.5 or less 1.5
Horizontal 1.3 or less 1.3
Spline hub & Play of hub spline in 0.06~1.15 0.45 Replace
drive pinion horizontal direction
Play of hub spline in 0.09~0.24 0.42
rotating direction
Diameter of hub +0.074
48
spline -0.060
Pressure Thickness 59.8±0.1 56.8 Replace
plate Flatness 0.05 or less 0.2 Repair or
replace
Strap pin hole -0.024 10.3
[0.01]
+0.006
Release lever height 77.5 +22 Adjust
(distance from clutch cover (Mutual difference in
height among four
to release lever) (0.1)
release levers :
0.7 or less)
Release lever pin to bushing clearance 0.016~0.111 0.12 Replace
Pressure Free length 93.0 ±1.0 Spring-8
spring 97.8 Spring-4
Load N(kgf) / Installed length 164.2±8% / 62.6 150 / 62.6 Spring-8
112.6±8% / 62.6 103 / 62.6 Spring-4
Clutch Clutch Play 34 to 41 - Adjust
control pedal Pedal shaft to bushing clearance 0.06 to 0.242 0.5 Replace
Return spring Free length 80 - Replace
Load N(kgf) / 39(4.0)/ 105.6 33(3.4) / 105.6
Installed length
Master Cylinder to piston clearance 0.04 to 0.125 [20.64] 0.15 Replace
cylinder Return spring Free length [75.3] 71.3 Replace
CH-8 CLUTCH

Unit : mm

Nominal value Remedy and

Check item Service limit
[basic diameter] Remark
Clutch Clutch Poppet spring Free length [21] 19 Replace
control booster Load N (kgf)/ 2.6(0.27) / 13 2.3(0.23) / 13
Installed length
Valve spring Free length [17] 15.5 Replace
Load N (kgf)/ 12(1.25) / 10 10(1.06) / 10
Installed length
Piston return Free length [112] 97 Replace
spring Load N (kgf)/ 88(9) / 55 75(7.6) / 55
Installed length
Fitting valve to relay valve piston clearance 0.03 to 0.08 [ø16] 0.11 Replace piston
Hydraulic piston to cylinder clearance 0.01 to 0.06 [ø22.2] 0.08
Power piston to tube-and-cylinder shell Excessively worn
clearance or damaged one
Bend of push rod of power piston Rod with a bend
exceeding 0.1mm
or rusted or
damaged one
Play of push rod of clutch booster 3.8 Adjust
TIGHTENING TORQUE CH-9

TIGHTENING TORQUE

Thread
Part to be tightened size Dia. Nm Kgf·m
x Pitch mm
Clutch Clutch cover bolt M10 x 1.5 32 3.3
mechanism Clutch housing bolt M10 x 1.5 32 3.3
Strap plate bolt M12 x 1.5 32-59 4.0-6.0
Lock plate bolt M8 x 1.5 9.8-15 1.0-1.5
Release fork set screw M10 x 1.25 33 3.4
Clutch pedal shaft bolt (nut) M12 x 1.5 48 4.9
Master cylinder bolt M10 x 1.25 33 3.4
Master cylinder offset bolt M12 x 1.25 78 8
Clutch Exhaust cover to end plate PT 1/4 9.8-49 1.0-5.0
booster End plate to connector M12 x 1.5 44-59 4.5-6.0
Push rod assembly to packing retainer attaching nut M14 x 1.5 20-29 2.0-3.0
End plate assembly and cylinder shell assembly M10 x 1.25 20-25 2.0-2.5
Bushing (installed to end plate) M14 x 1.5 7.8-9.8 0.8-1
Upper valve body to end plate M6 x 1.0 3.9-5.9 0.4-0.6
Upper valve body to end connector M24 x 2.0 20-29 2.0-3.0
End plate assembly to hydraulic cylinder assembly M32 x 1.5 29-39 3.0-4.0
installation
Relay valve assembly to end plate assembly M22 x 1.5 15-24 1.5-2.5
installation
Booster bracket attaching bolt M14 x 2.0 93 9.5
Oil hose union bolt M16 x 1.5 43-65 4.4-6.6
Air pipe union bolt M14 x 1.5 35 3.6
Air pipe connector installation M16 x 1.5 38-50 3.9-5.1
Air bleeder plug - 2.9-6.9 0.3-0.7
Air pipe nut M20 x 1.5 180 18.6
CH-10 CLUTCH

SPECIAL TOOLS
Tool(number and name) Illustration Use

09411-8A000 For disconnecting and centering

Clutch alignment arbor clutch disc

1.9
ø4
D118A00A

09411-76000 For disconnecting and installing

Clutch installer clutch cover

D117600A

09411-87200 Adjusting release lever height

Clutch lever aligner

25

D118720A
SERVICE PROCEDURE CH-11

SERVICE PROCEDURE
Clutch Proper
Removal and Installation
Removal
1. Disconnect the control rods and associated parts around the
09411-8A000
transmission.
2. Remove the propeller shaft. Stopper bolt AC41013
3. Remove the transmission.
4. Remove the pressure plate and lever assembly.
When removing the pressure plate and lever assembly, secure
the pressure plate with the special tools, Stopper Bolt and Plain
Washer.
Before removing the pressure plate and lever assembly, install
the special tool(09411-8A000) to prevent the clutch disc from
dropping.
NOTE:
1. Before removing the clutch, be sure to install the stop-
per bolt and plain washer to prevent to strap plate from
being damaged.
2. Use the stopper bolt (M10 x 1.25 - 85 with effective
length 30 mm or more) and plain washer (for M12
threads) commercially available.

Installation Part number

stamped here
1. Using the special tool(09411-8A000), Install the clutch disc.
Pilot Clutch disc
NOTE: bearing
When installing the clutch disc, make sure that it is in-
stalled in the correct direction: install it so that its side
with the part number stamped is visible.
Flywheel
Clutch Alignment
Arbor AC41015

2. Secure the pressure plate of the pressure plate and lever as- Stopper bolt
(4places : M10 x 1.25)
sembly with the stopper bolts, then install the clutch, aligning it
with the knock pins in the flywheel.
NOTE:
1. Before installing the clutch, check and clean the fly-
wheel and repair or replace as necessary.
2. Tighten bolts evenly, in the diagonal order.
3. After installation, be sure to remove the stopper bolt. AC41017
CH-12 CLUTCH

3. Inspection of release lever plate height.

Using the special tool(09411-87200), check the height of the
release lever plate and the clutch cover.
NOTE: 09411-87200

The adjustable type has no release lever plate, so check

the clutch cover and release lever for height.

AC41019
SERVICE PROCEDURE CH-13

Disassembly and Inspection

Assembled thickness
(where installed)
Free length Item NV L
NV
assembled thickness
Flatness 0.05mm or less 0.2mm
11.4 ± 0.3mm 11.8 ± 0.3mm
Thickness 60 ± 0.1mm 57mm
Hub spline diametric clearance Strap bolt hole 12 +0.024 mm 12.5mm
- 0 .006
NV 0.06 to 0.195mm
L 0.42mm

Grind to correct
flatness.
18
Thickness
Load/installed NV : 109/55.8mm
Strap bolt hole 9
length L : 102/55.8mm
10 11 7
6 Squareness NV : 3.0mm
5
15 16 L : 4.5mm
12
8
1 17
13
14
Clearance from
release lever
NV 0.016 to 0.111mm 4
3
2

Runout below NV
Depth to rivet head
NV 2.2 to 2.8mm Flatness Horizontal Vertical NV ... Nominal Value
0.3 to 1.2mm 1.0mm 1.5mm L ... Limit
L 0.2mm

Disassembly sequence
1. Clutch disc 10. Spring seat
2. Lock bolt 11. Adjusting washer
3. Lock washer 12. Release lever pin
4. Support nut 13. Release lever pin
5. Strap bolt 14. Lever support
6. Strap support washer 15. Return spring
7. Strap washer 16. Release lever
8. Clutch cover 17. Bushing
9. Pressure spring 18. Pressure plate

AC41021
CH-14 CLUTCH

Disassembly and Inspection Procedure

1. Removal of clutch cover Strap bolt
1) Compress the pressure spring with the stopper bolts and, Support nut

at the same time, remove the strap bolts, support nuts, and
other parts.

Support bolt AC41023

2) Put alignment marks on the clutch cover and pressure plate. 09411-76000
Compress the pressure spring using the special tool(09411-
76000) and at the same time remove the stopper bolt.
3) Gradually loosen the handle of Clutch Installer to remove
the clutch cover.

Align stopper bolts

with plate holes
AC41025

2. Inspection of clutch disc

1) Facing wear
Measure the assembly thickness of facing and the depth
from facing surface to rivet head or height to cup. If the
Depth to rivet head
measurement is below the limit, replace the clutch disc
assembly.
Assembled
Depth from facing Standard value Limit
thickness
surface to rivet head 2.2~2.8 mm 0.2 mm AC41027

2) Clutch disc runout Dial indicator

Using a runout tester, measure the clutch disc runout. If
the measurement exceeds specification, correct or replace
the clutch disc.
Standard value Limit
Runout Vertical direction 1.5 mm or less 1.5 mm
Horizontal direction 1.3 mm or less 1.3 mm
AC41029

3) Spline play in turning direction

Using a piano wire, measure the play in the turning direc-
tion of the clutch disc boss splines and transmission drive
pinion splines. If the limit is exceeded, replace the clutch
disc.
Standard value Limit
Hub spline play
0.09~0.24 mm 0.42 mm
AC41031
SERVICE PROCEDURE CH-15

3. Inspection of pressure plate

1) Measurement of thickness
Pressure plate
Measure the pressure plate thickness and if it is below the thickness
limit, replace.

Pressure plate
AC41033

2) Measurement of flatness
Measure the flatness of the pressure plate friction surface. Pressure plate
Regrind or replace if the limit is exceeded.

AC41035

3) Strap bolt fitting hole I.D. Strap bolt hole

Measure the I.D. or strap bolt fitting hole in the pressure
plate and, if the limit is exceeded, replace

AC41037

4. Inspection of release lever Release lever

Measure the release lever pin O.D, and busing I.D..
If the clearance exceeds the limit, replace the release lever.

I.D
Release lever pin

O.D AC41039

5. Inspection of pressure spring Squareness

Measure the free length, squareness, and installed load of the
pressure spring. If the measurement is below the limit, replace
Free length

the spring.

Pressure spring
AC41041
CH-16 CLUTCH

Reassembly and Adjustment

40Nm
(4.1 kgf·m) 3.9 to 4.9Nm
(0.4 to 0.5 kgf·m)
1 2 9.8 to 15Nm (1.0 to 1.5 kgf·m)
8
14
4
3
13
5 39 to 49Nm
12 (4 to 5kgf·m)

16 6
11
15
7
10 17
18 9 21Nm
39 to 49Nm (2.1kgf·m)
(4 to 5kgf·m)

Reassembly sequence
17→18 16
↓ ↓
19 14→13→12→11→10→9→8→7→6→5→4→3→2→1
↑
15
AC41043

Reassembly Procedure
1. Whenever the pressure plate friction surface is corrected, in-
sert adjusting washers of thickness equivalent to correction Adjusting washer
amount.

Correction amount of Adjusting washer

friction surface thickness
Less than 1mm None required
AC41045
1mm or more and One 1.2
less than 2mm 09411-76000

2mm or more and Two 1.2 mm or one 2.3 mm

less than 3mm

2. To install the clutch cover, align the alignment marks using the
special tool(09411-76000), temporarily tighten the stopper bolts.

Align stopper bolts

with plate holes AC41047
SERVICE PROCEDURE CH-17

3. With the pressure spring compressed by the stopper bolts, in-

stall the strap bolt, support nut, and other parts. Strap
Support nut

Stopper bolt AC41049

4. After installing the clutch, check the clutch cover and release
lever for height using the special tool(09411-87200).
NOTE: 09411-87200
On the adjust type, check the clutch cover and release le-
ver for height.

AC41051

Clutch Pedal
Removal and Installation
1. Referring to Replacement of Brake Fluid in Clutch System
Section, discharge brake fluid from the clutch reservoir tank Clutch master
and pipings. cylinder
Clutch pedal
2. Remove the clutch hose and clutch tube from the clutch mas-
ter cylinder.
NOTE: AC41053
Plug the clutch hose and clutch tube after they have been
removed to prevent brake fluid from leaking.
Clutch switch
3. Disconnect the clutch switch connector.

AC41055

4. Remove the clutch pedal assembly.

5. To install, reverse the order of removal and pour brake fluid
after reinstallation.
6. Bleed the clutch system of air.

AC41057
CH-18 CLUTCH

Disassembly and Inspection

Pedal shaft bushing clearance 4

BD 20mm
NV 0.07 to 0.284mm 10
11
L0.5mm

1
2
Lost tension
12 NV 54N (5.51 kgf)/103.5mm
L 49N (4.96 kgf)/103.5mm

9
3

7
8
5 BD ... Basic Diameter
NV ... Nominal Value
L ... Limit
6
Disassembly sequence
1. Clutch switch 7. Bushing NOTE:
2. Return spring 8. Clutch pedal To loosen toe offset bolt, turn the nut with the
3. Stiffener 9. Pedal pad bolt head secured in position.
4. Bracket (R.H.) 10. Bushing
5. Clevis pin 11. Pedal shaft
6. Clutch master cylinder 12. Bracket (L.H.)
AC41059

Inspection Procedure
1. Inspection of return spring
Using a spring tester (for tensile load), measure the load (tensile
load) at the installed length. If the measurement is below the
limit, replace the return spring.

AC41061

2. Measurement of clearance
Measure the bushing I.D. and pedal shaft O.D. if the clearance Bushing
exceeds the limit, replace the bushing and the pedal.

Pedal shaft I.D.

O.D.

Clutch
Pedal
AC41063
SERVICE PROCEDURE CH-19

Reassembly and Adjustment

10
5

7 2
1.9~2.8kgf·m 3.4~5.0kgf·m 11
1.9~2.8kgf·m

3
8 m 226.5mm
3.9~5.5kgf·m 8 m
6~
B
6 4

2.0~3.0kgf·m
m 12
+5 m
0 -0
15

Reassembly sequence 1. Clutch switch 7. Ball joint pushrod

2. Coil spring 8. Clutch pedal
1
↑ 3. Stopper rubber 9. Clutch pedal pad.
8→7→9→3→2
↑ 4. Clutch pedal bracket(RH) 10. Clutch switch nut
6→5→4 5. Nut 11. Push rod nut
6. Clutch master cylinder

KCYCH01A

Adjustment of Clutch Pedal

1. Turn the clutch switch until clutch pedal stroke is within stan-
dard value
+5
Clutch pedal stroke : 150 -0
mm

2. Turn the ball joint push rod nut of master cylinder until clutch
pedal play is within standard value and tighten the push rod nut
to the specified torque

Clutch pedal play : 6-8mm

Push rod nut : 19-27Nm(1.9-2.8kgf·m)
CH-20 CLUTCH

Clutch Master Cylinder

Disassembly and Inspection

Lost tension
NV 75.3mm
L 71.3mm

Checks damage, and

deformation in seat 1

10
8
2
5
6
Disassembly sequence
7 1. Push rod
2. Boot
9 3. Supply valve stopper
4. Gasket
Clearance 5. Piston stop ring
BD 20.64mm 6. Piston stop plate
NV 0.04 to 0.125mm 7. Piston
4
3 L 0.15mm 8. Return spring
9. Cylinder
10. Nipple
BD... Basic Diameter
11. Air breather
NV...Nominal Value
12. Cap
L ... Limit
ECYCL02A

Disassembly Procedure
Compressed air
To remove the piston assembly from the cylinder, plug the nipple
and send compressed air from the union at the back of the cylinder. Cylinder

Piston assembly

AC41071

Inspection Procedure
1. Inspection of piston and cylinder
Measure the cylinder I.D. and piston O.D. Replace the parts if
the clearance exceeds the limit.

AC41073
SERVICE PROCEDURE CH-21

2. Inspection of springs
Measure the installed load of each spring and replace it if the
limit is not reached.

AC41075

Reassembly Procedure
Install the piston cup to the piston. Cup guide
Piston

Piston cup

AC41079
CH-22 CLUTCH

Clutch Booster
Removal and Installation

Clutch booster

Snap pin

40Nm(4.1 kgf·m)

Clevis pin

40Nm(4.1 kgf·m)

Oil pipe

JJR41-053

Removal
1. Remove brake fluid from the clutch system, then remove air
pipes and oil pipes from the clutch booster.
NOTE:
Plug the open clutch booster ports and pipes removed to
prevent entry of dust and dirt.

JJR41-054

2. Remove the clevis pin from the end of the push rod of the clutch
booster to disconnect the connection of the release fork shaft
lever.
Push rod

Clevis pin

Release fork shaft lever

JJR41-055
SERVICE PROCEDURE CH-23

3. Clutch booster bracket

Remove the mounting bolts and remove the clutch booster from
the transmission.

JJR41-056

Installation
1. Install the clutch booster to the transmission and tighten the
mounting bolts to specification.

Specified torque : 33Nm(3.4kgf·m)

JJR41-056

2. Connect the clutch booster push rod to the release fork shaft
lever. Then, install air pipes and oil pipes to the clutch booster
and tighten them to specification.
Next, fill the clutch system with brake fluid and bleed the clutch
system of air, referring to Replacement of Brake Fluid in Clutch
System and Bleeding of Clutch System Section.

JJR41-054
CH-24 CLUTCH

Disassembly and Inspection

Fitting valve to relay valve

piston clearance
BD 16
NV 0.03 to 0.08
Load/installed length L 0.11 *30
NV 12.3 (1.25 kgf)/10 *31
L 10.5N (1.06 kgf)/10 11
10 9
8
Load/installed length 7 Hydraulic piston to hydraulic
5
NV 2.6N (0.27 kgf)/13 6 cylinder clearance
4 13
L 2.2N (0.23 kgf)/13 29 BD 22.2
2 3 24
27 28 12
26 NV 0.01 to 0.06
1 25 L 0.08
23
22
21 Alignment (or bend)
20
19 L 0.1 or less
16 14
18
17
Disassembly sequence
1. Connector 17. Piston
2. Poppet spring 18. Packing cup
3. Poppet valve 19. Guard assembly 15 Load/installed length
4. Upper valve body 20. Retaining ring NV 89N (9 kgf)/55
5. Diaphragm assembly 21. Washer
L 75N (7.6 kgf)/55
6. Valve spring 22. Hydraulic cylinder
7. Plate 23. Hydraulic piston
8. Retaining ring 24. Packing cup
9. Relay valve piston 25. Retaining ring
10. Packing cup 26. Washer
11. Fitting 27. Retainer
12. End plate assembly 28. Packing cup
13. Oil seal 29. Washer
14. Cylinder shell assembly 30. Exhaust cover BD ... Basic Diameter
15. Power piston spring 31. Air bleeder screw NV ... Nominal Value
16. Push rod assembly L ... Limit
* Parts 30 and 31 should not be removed unless where necessary.
AC41091

Disassembly Procedure
NOTE:
1. Be sure to remove mud, dust, and dirt from the surfaces on which you are going to work.
2. Make alignment marks on joints to ensure that parts are reassembled correctly.
3. Keep disassembled parts in order to facilitate reassembly.
4. Replace rubber parts with a repair kit whenever they are disassembled.
Clean metal parts with trichloroethlyene, metachloroethlyene, etc.
SERVICE PROCEDURE CH-25

5. To clean rubber parts, use alcohol.

6.9 to 12.8 Nm
(0.7 to 1.3 kgf·m) 9.8 to 49 Nm
30(1.0 to 5.0 kgf·m)
Gasket *3
7.9 to 9.8 Nm
4.9 to 7.9 Nm
(0.8 to 1.0 kgf·m)
(0.5 to 0.8 kgf·m)

19 to 24 Nm
16 to 24 Nm
(2.0 to 2.5 kgf·m)
(1.5 to 2.5 kgf·m)
*2 Sliding surface
Gasket *3
*1 Sliding surface 12 9 10 8 31 1 17 5 6 4 3
1 19 to 24 Nm
(2.0 to 3.0 kgf·m)
15 2
3.9 to 5.9 Nm
18
(0.4 to 0.6 kgf·m)
14 19

19 to 29 Nm
(2.0 to 3.0 kgf·m)
16
17
13 29 28 27 26 25 24 23 22 21 20

*2 Sliding surface 29 to 39 Nm
*2 Sliding surface
(3.0 to 4.0 kgf·m)

Reassembly *1 : Apply airmaster paste.

After reassembly, install the clutch booster to the vehicle and check for *2 : Apply rubber grease.
possible air or oil leak. *3 : Apply silicone oil.

Reassembly sequence

23→24 9→10→11

22→21→20

12→13→31→30→29→28→27→26→25 15 14 8→7→5→6→4→3→2→1→19

16→17→18

AC41093
CH-26 CLUTCH

Reassembly Procedure Retaining ring Valve fitting

1. Install the packing cups to relay valve piston with the packing
cup lips back-to-back.

Acking cup O-ring

Relay valve piston AC41095

2. Coat the hydraulic piston with rubber grease and, cup Insert Cup Insert Guide Hydraulic piston
Guide, install the packing cup to the hydraulic piston.

Packing cup

Hygraulic piston

Packing cup AC41097

3. Insert the piston, into which packing cups are installed, into the Packing cup
Hydraulic piston
hydraulic cylinder.
NOTE:
When inserting the piston, use care not to allow the packing
cup lips to raise.

Hydraulic cylinder
Piston stop whaser
Retaining ring AC41099

4. Install the oil seal, piston cup, and other parts into the end plate.

O-ring

Retaining ring

Seal retainer

Packing cup

End plate

Oil seal

Spacer washer

washer

AC41101
SERVICE PROCEDURE CH-27

Clutch Housing Assembly Push rod

Removal
1. Remove the clevis pin from the end of the clutch booster push
rod to disconnect connection to release fork shaft lever.
NOTE: Clevis pin
Hold the push rod by hand as it jumps out when the clevis
Release fork
pin is removed. shaft lever
AC41103

12

Deformation, wear
9
7
4

3 Removal sequence
Rotating
1. Tube
condition
2. Return spring
3. Clutch shifter
2
Test 4. Elbow
ten- 1 5. Clutch release bearing
11
6 10 sion 6. Set screw
7. Clutch release fork
8. Release fork shaft
9. Needle roller bearing
10. Grease nipple
11. Connector
12. Clutch housing

AC41105
CH-28 CLUTCH

Installation

4
3
Apply the
grease on the
release bearing
5
8

1
2
9
Reassembly sequence 7 6
8
↓ 4
11→10→4→9 16 2→1
↑ ↑
7 5←4←3 10 11
AC41107

Installation Procedure
1. Replacement of oil seal
Oil seal installer
Install the oil seal to bearing retainer using oil seal installer.

Bearing Retainer
AC41109

2. Replacement of needle roller bearing

Install the needle roller bearing into the clutch housing and us-
ing a hammer, tap it into position as shown.

Needle roller bearing

Dust seal side
Needle roller bearing
Installer AC41111

3. Install the clutch housing to the transmission case.

Tighten the clutch housing mounting bolts in diagonal order,
evenly, in two or more steps, before tightening to specification.

AC41113
SERVICE PROCEDURE CH-29

Replacement of Brake Fluid in Clutch System

Clutch reservoir tank

Clutch pedal

Clutch master cylinder

Clutch
booster

AC41115

1. Fit vinyl tube to the air bleeder of the clutch booster and put the
other end of the vinyl tube in an empty container. Vinyl tube
Loosen the air bleeder of the clutch booster and depress the
clutch pedal until no more brake fluid flows out.

JMS41-078

2. Prepare a container which can be used as a temporary reservoir

Vinyl tube
tank.
Connect the temporary reservoir tank and the air bleeder of
the clutch master cylinder with an vinyl tube.
3. Loosen the air bleeder of the clutch master cylinder and tighten
it when the brake fluid flows out from the air bleeder of the
clutch booster.
Remove the temporary reservoir tank and vinyl tube. JMS41-078

4. While pouring in fresh brake fluid into the reservoir tank, con-
tinue to depress the clutch pedal until the fluid of the clutch
system is replaced with the fresh fluid (the fluid flowing out
changes in color).
NOTE:
Do not feed brake fluid until its level exceeds "MAX" on
the brake fluid reservoir tank.
5. Remove the vinyl tube, tighten the air bleeder, and install the
protector.
CH-30 CLUTCH

Bleeding of Clutch System

Clutch reservoir tank

Clutch pedal

Clutch master cylinder

Clutch
booster

AC41121

1. Drain the brake fluid from the clutch reservoir tank

Vinyl tube
2. Remove the air bleeder protector from the clutch booster and,
instead, fit one end of a transparent vinyl tube.
Place the other end of the pipe in a container filled with brake
fluid.
3. Prepare a container which can be used as a temporary reservoir
tank.
Connect the temporary reservoir tank and the air bleeder of JMS41-078

the clutch master cylinder with a vinyl tube.

4. Fill the temporary reservoir tank with fresh brake fluid and loosen
the air bleeders of the clutch master cylinder and clutch booster.
5. When only few air bubbles are found in the brake fluid flowing
out the air bleeder of the clutch booster.
6. Tighten the air bleeder of the clutch master cylinder and then
remove the temporary reservoir tank.
7. Pour brake fluid into the clutch fluid reservoir tank up to the
"MAX" level.

NOTE:
Never leave the clutch fluid reservoir tank empty during
the procedure.

ECYCH01A
SERVICE PROCEDURE CH-31

8. Pump the clutch pedal several times and keep it depressed

and, at the same time, loosen the air bleeder to discharge brake
fluid. Then, immediately, tighten the air bleeder and release
the pedal.

JMS41-077

9. Repeat step (4) until the brake fluid runing clear from the air
bleeder containing no air bubbles.
Then, tighten the air bleeder securely.
NOTE:
Push rod play should be 3-4mm.

JMS41-085

+2
A:24.5 -1
mm

JMS41-085-1

10. Check for the level of fluid in the clutch reservoir tank and add
fluid as necessary up to the “MAX” level.

ECYCH01A
CH-32 CLUTCH

TROUBLESHOOTING
Symptom Probable cause Remedy Remarks
Clutch drags Defective operating mechanism
when • Leaks from oil line Repair or replace
disengaged defective parts
• Air in oil line Bleed the system
• Improper clutch pedal play Adjust
• Malfunctioning clutch master cylinder Repair or replace
• Malfunctioning clutch booster
Defective clutch proper
(Disassemble and check clutch assembly)
• Damaged or poorly lubricated pilot bearing Replace or lubricate
• Damaged release bearing Replace
• Uneven height of release lever or its damage Adjust height or
replace
• Defective clutch disc Replace clutch disc
• Damaged or deformed clutch disc assembly
• Worn or rusty splines in transmission drive Replace or repair (Replace drive pinion
pinion, and clutch disc hub defective parts or input shaft)

• Distorted or damaged pressure plate and Grind or replace

intermediate plate (double-disc)
Distorted or damaged flywheel
Clutch slips Defective operating mechanism
• Improper clutch pedal play Adjust
• Clutch pedal return spring losing proper tension Replace
• Malfunctioning clutch master cylinder Replace defective
• Binding piston or piston cup parts
• Plugged fluid inlet and outlet Disassemble and clean
• Return spring losing proper tension Replace
• Clutch booster return spring losing tension
• Malfunctioning clutch booster Replace defective
• Binding piston or piston cup parts
• Plugged fluid inlet and outlet Disassemble and clean
TROUBLESHOOTING CH-33

Symptom Probable cause Remedy Remarks

Clutch slips Defective clutch proper
(Disassemble and check clutch assembly.)
• Uneven height of release lever Adjust
• Pressure spring losing proper tension Replace
• Defective clutch disc Replace clutch
• Worn facing disc assembly
• Deformed clutch disc Replace clutch
disc assembly
• Hardened facing Remove hardened
surface or replace
clutch disc assembly
• Oil in facing Remove oil or replace
clutch disc assembly

• Distorted or damaged pressure plate Grind or replace

Distorted or damaged flywheel

Clutch is Defective operating mechanism
not smoothly • Malfunctioning clutch pedal Lubricate or repair

engaged • Clutch pedal return spring losing proper tension Replace

• Malfunctioning clutch master cylinder Replace defective

• Binding piston or piston cup parts

• Plugged fluid inlet and outlet Disassemble and clean

• Return spring losing proper tension

• Clutch booster return spring losing proper tension Replace

• Malfunctioning clutch booster Replace defective

• Binding piston or piston cup parts

• Plugged fluid inlet and outlet Disassemble and clean

Defective clutch proper

(Disassemble and check clutch assembly)
• Defective clutch disc Replace clutch disc

• Distorted facing assembly

• Hardened facing Remove hardened

surface or replace
clutch disc assembly

• Loose rivet Replace clutch disc

assembly

• Oil on facing Remove oil or replace

clutch disc assembly

• Binding clutch disc splines Correct or lubricate

splines
CH-34 CLUTCH

Symptom Probable cause Remedy Remarks

Clutch is • Clutch disc torsion spring losing proper Replace clutch disc
not smoothly tension or broken assembly
engaged • Uneven height of release lever Adjust
• Pressure spring losing proper tension Replace
• Distorted or damaged pressure plate Grind or replace
Distorted or damaged flywheel
Clutch is Worn, damaged, or poorly lubricated pilot bearing Replace or lubricate
noisy when Worn, damaged, or poorly lubricated release bearing
disengaged Defective clutch disc
• Worn clutch disc splines Replace clutch
• Clutch disc torsion spring losing proper tension or broken disc assembly
Bent strap plate Replace clutch cover
Clutch is Defective clutch disc
noisy when • Clutch disc torsion spring losing proper Replace clutch
engaging tension or broken disc assembly
• Worn clutch disc hub splines
Pressure spring losing proper tension Replace
Low idle speed Adjust
Vehicle Poorly lubricated clutch control mechanism Grease the
shudders clutch shifter
when starting Engine mounting rubber losing tension Replace
Defective clutch housing assembly
(Remove as the transmission assembly)
• Defective clutch release bearing Replace or lubricate
• Binding or damaged clutch shifter Replace or lubricate
• Deformed or worn clutch release fork Replace
Defective clutch proper
• Uneven height of release lever or its damage Adjust height
or replace
• Loose strap plate locking bolt Torque to
specification
• Flatness exceeding limit Repair or replace
• Defective clutch disc
• Oil on facing Clean or replace
• Flatness or runout exceeding limit Correct or replace
• Facing not in even contact Correct or replace
• Worn splines Apply grease to
splines or replace
Flywheel assembly flatness out of specification Correct or replace