Clutch System GENERAL sesso CLUTCH SYSTEM ssocH CLUTCH SYSTEM GENERAL SPECIFICATIONS sane [latch disc Typo oy single ite Otter Dameter rim i) 20 (948): 4055 TOL, SIRIUS, T2 254 (987): A25 TC! Facing mates Nonasbowos| Spine 25 teh Couto over “pe Diaphragm spring te Seting baa Np, ts) oor (e159), porting sytem Hysralic Sytem Soeconterng ype sme (in) 1905 (075) SERVICE SPECIFICATIONS suse em ‘Standard Limit ‘uh pedal hegre ‘08 (68) ‘teh pedal ro pay eisyo2t05t) Distance between utc pedal and foomoard when 55 (216) oc moco ich is dsengagod (tc poaal stoke 185.62) Cloararcebetwoon sich master cling and piston 015 (0008) {luton se tac et snk 03 (012) ram) TORQUE SPECIFICATIONS com im [ve tem er ‘Guoh aa | we-28 90-260 a= 28 ‘Gen master evtader moun bok ‘Gen fe tare nt {Glues rtease eyinder mounting bot {Gute tsease cyinr eye bat {Gucs flease cyinder Baader screw ‘Giten cover atacnng bat (Se chamber mauming botcus GENERAL ‘SPECIAL TOOLS cue \PSjnice il not espond to engine Soeed ung ace + suf wehiee spe03 1 Uiskor power ouing uni vg cl abr a a) ison ie arr0 aig a ach Ga won Se Speen oer aes ‘- — TROUBLESHOOTING ——— (Sma reba ane 59 ed reweave wear of cluch Jae [ardaned euch de cea con ia Sarraped pressure lt o Hywel ‘Hos or broken pressure sna | Baca goa siting (gear roe auzng siting) Excessive ouch pedal Fes Day ad cach a, or mid nC) Cnusvatmearen eareson orth ase epine | ple aces vibration (Boron ofcuoh GAG eslace Gian Tran dicho nt ueed | nuit ay of con pe et oy Excessive wear of uch dic 65nd epee “craw pand wher auch |Unmvalwesr ardor ane alesse earra | Fe? fe Saorgated eer ardwhen cach | notre on be sing secs Fone fe esonoaged earn soo rreprnsiaie eka asserbyorlase barg | Feat Trace head when vias | Damaged plot bearing eiace fo podem rol wi xen para engaged Tard pedal ofr ‘paar Wbricaon of Ouch at ineeen Wbreatn of Cuchi ine ‘recent ubreaton of euch lease vo: hacus CLUTCH SYSTEM CLUTCH SYSTEM CLUTCH COVER AND DISC COMPONENTS anon Removal steps oN {Fananisoe asonay (aa2t¢m 180m 2 Cite cove 5 utc deo” Note Reverse the removal procedures orinsal REMOVAL csc INSPECTION soc "sort 1 Spec Toon he My-uhea! pit bearing CLUTCH COVER ae 1. Check tn phragm spring ti for wear © Steceaiencoertowenntotamtanyng ens vos iseces aa 2 Famers te clteh cover Then pull ou the Speci 9. Check ho pressure plate sua or damage, Tool and remove the chich ce. 4 Check pivot ng for wear. Yy\\\ Daore YG Bese: aCLUTCH SySTEM cuuTeH aise 1. Chack facing er oose et, unavn contac, deta ‘rion due seizure, ana resencs of to 0380, 2 Check sion spag and tion washer for lose nos, fatigue and cane ‘CLUTCH DISC FACING WEAR MEASUREMENT 1 Uso clr gauge to measure the dimension rom the Tacng sree fhe mit head “Grats 08 mm (0002 2. ine rmeasired vl ibelow tha ims replace etch ee 1 facing is excessively wor, check Anes! and ich cover pressure pao for waar cus NE — INSTALLATION. sso ‘Lures oisc 1. Appr spi groas0 to cluch eae spine, HYUNDAI Genuine Grease 2. Use the Spica Tel ost cluen a oho 8. _Whon nstalng cuts die, be era that ura hav Ing manutoxrore stamped mar (neatod bya row inte lusraton on proteus pace side cure cover Insal tth cor wth dows! pn hoe in allgnnent wth ‘wel pininfywneel and ighten bls radia na cs ‘ree fationcHs CLUTCH MASTER CYLINDER COMPONENTS sn * Disassembly stops 1, Piston topper rng. a 2 Pusnros 5 Paton ssomty 2 Claen manar oye note Fevers the desssombly procedures to reassemble. DISASSEMBLY cous 1 Remove the piston stoppor rn. 2 Remove he piston assert, A caurion Do not clamage the master cylinder body and pis- ton assembly. Do not dlsassomble piston assem by CLUTCH SYSTEM,CLUTCH SYSTEM INSPECTION ssa 2 a 6 ‘Chace inside cylinder body for ust scars [Check piston cup for moar delrmaton, (Check piston for ut or car (Check elie ube connection part er logging oasur tne mse vnc inside lamers tne pston outa ameter wih eyner gauge and a pcre Unis oe mm (05m) — (nore ess he site ameter of te mast yndr ‘tte paces eto, mee, dp) eh orpondcutar decors. 1 master eynderto-pison clasrance exceeds the mi replace tne master ovine andr piston a sy REASSEMBLY 1. Apply specie ouch td tthe inner sue ofthe ‘mast ono body andto theatre perpery othe piston ser. ‘Speci cute tu ‘Brake fsa SAE J1709 (DOT 3 0 OOT 4) j 2. Apply th speed sealant to contact sutace of ie Spee ‘alan: Metal Rubber #2.cus. CLUTCH PEDAL CLUTCH PEDAL INSPECTION AND ADJUSTMENT ie 1. Measure he clten pada neigh andthe ech pda book, Clute peda heght (Gnore Cue pec hig nonagustat. ie hgh 8 Sutil he stan alu, hook or ered peal Bracke, tard replace pars as oqued << 2. Gon that he lsh dale pay anc th cla ‘noetothe foo board wen tu teh conga, {re win the standard aoe ‘Clutch pedal roe play (Including cews pin pay) Distance between the clutch pedal and the toor- board when the utch = cieengaged San value 65 mim B16 mn) oro CLUTCH SYSTEM Rosanogutan resis mcg 3. tthe cutch peda pay exceeds He stand van usta py wih no dub nut on he push oon masa eying se iS cauriow ‘Be careful otto push the pushrod toward the ‘master eynder. Quore “Adhstrentfthecuch peal eeplaymustbomade tying pun od debe aon ast po afer sisonbingCLUTCH sysTEM BLEEDING \ihenever he clutch tube, he ech hase, andor the ‘ulema vindr have Bon remus oF # lloh ada spongy, Deed he system, By caution Use the spected brake Mui Avoid using a mix- {ura ofthe specification Muld and other Mul. Spastied bake fs Brak fd SAE 1703 (DOT 3 o DOT 4)caso cure ssn COMPONENTS come 2535 290360, 1825) a = ‘TORQUE : Nm (kgsom, Ib)(CLUTCH SySTEM REMOVAL, 1 Loosen nt on the etch shat blot romoving the Spl pao radu he um over spent 2. Romove the spit pin of ho spring assist 0. INSPECTION soso 1. heck he pola shat bushing fr wear 2, Chock he pode! shat or bend {8 Chace pda am for Bend or torsion 44. Check he clutch tube and reservar hae or racks or egg. 5. Chock he tumover sting for deterioration 6 Chock ha peal pact tor camage o weet INSTALLATION. cs» MASTER CYLINDER, Muipupose grease 'SUN LIGHT #2 or RETINAX A cu ‘CLUTCH PEDAL AND CLUTCH SHAFT ‘Apply seciod ease oa connecting and sing pars below aesembiy Specie grass ‘Chassis proase SAE Jo10, NGI NOO ATTACHING NUT AND SPRING ASSIST ROD _Aterinstalng he uch shaft and th teh pedal. install ‘ho spring and he spring ait od,cHt2 CLUTCH RELEASE CYLINDER COMPONENTS: sams Nore Number show order of removal For reassembly, reverse order of removal DISASSEMBLY smn 1. Before romoving the ch tubo, charg the cach Inspection 1. heck the clutch eease cylinder th leakage 2. Chock ne clutch release ey Dot or aamage. REASSEMBLY essen 1 Apply coating fhe spentod gransa to te contact pars ofthe release fore and ease yids push fos inp grease SAE J310, NLGI NO2 CLUTCH SYSTEM, Release cyinder Spree 2. Fill row tank wih spuds Hid aor ataching ‘sun be, ‘Spciiod geass (Brak fd SAE 1708 (DOTS or DOT 4) 3. Page sant check or eas