CLUTCH

C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

CL

CONTENTS
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
CLUTCH PEDAL ........................................................ 3
Conponents .............................................................. 3
CLUTCH MASTER CYLINDER .................................. 4
Removal and Installation .......................................... 4
INSTALLATION ..................................................... 4
CLUTCH PIPING ........................................................ 5
Components ............................................................. 5
E
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL..... 6 F
Components ............................................................. 6
SERVICE DATA AND SPECIFICATIONS (SDS) ........ 7
Clutch Control System .............................................. 7 G
Clutch Pedal ............................................................. 7
Clutch Disc ............................................................... 7
Clutch Cover ............................................................. 7
H

Revision: 2005 September CL-1 C11

 PRECAUTIONS

PRECAUTIONS PFP:00001

Service Notice or Precautions GCS0017A

● If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts may
damage CSC seal and may cause clutch fluid leakage.
● Do not disassemble master cylinder and CSC.

Revision: 2005 September CL-2 C11

 CLUTCH PEDAL

CLUTCH PEDAL PFP:46540

A
Conponents GCS0009V

CL

PCIB1492E

1. Clutch pedal assembly 2. Clip 3. Clutch switch J

Refer to GI-11, "Components" , for the symbols in the figure.

Revision: 2005 September CL-3 C11

 CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Removal and Installation GCS0009X

INSTALLATION
1. Tilt master cylinder clockwise by 45° and insert it to the mount-
ing hole. Rotate counter clockwise and secure it. At this time,
nipple is upward of the vehicle.
2. Install master cylinder rod end to clutch pedal.

SCIA1286E

3. Install clutch tube (1) into connector of master cylinder (2) until it
stops.
4. Install lock pin (3) into connector of master cylinder (2) until it
stops.
5. Fill new clutch fluid according to the following.
a. Fill reservoir tank with new clutch fluid.
CAUTION:
Keep painted surface on the body or other parts free of
clutch fluid. If it spills, wipe up immediately and wash the
affected area with water. PCIB1500E
b. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.
c. Push the lock pin (1) of the bleeding connector (2).

PCIB1495E

d. Slide clutch tube (1) in the direction of the arrow as shown in the
figure.
Dimension “A” : 5 mm (0.20 in)
e. Depress clutch pedal slowly to full stroke and then release it.
Repeat this until new clutch fluid comes out.
CAUTION:
● Hold it to prevent releasing clutch tube (1) from bleeding
connector when fluid pressure is applied in the tube.
● Monitor clutch fluid level in reservoir tank to make sure it
does not empty. PCIB1496E

f. Place clutch tube (1) and lock pin (2) back into position with clutch pedal depressed.
g. Bleed the air from the clutch hydraulic system.

Revision: 2005 September CL-4 C11

 CLUTCH PIPING

CLUTCH PIPING PFP:30650

A
Components GCS0009Z

CL

PCIB1499E

1. Clutch tube 2. Lock pin 3. CSC E

4. Clutch damper 5. Master cylinder 6. Clutch pedal

Revision: 2005 September CL-5 C11

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100

Components GCS000A0

PCIB1501E

1. Flywheel 2. Clutch disc 3. Clutch cover

A: First step
B: Final step

Refer to GI-11, "Components" and the followings for the symbols in the figure.
: Apply lithium-based grease including molybdenum disulphide.

*1: Do not clean in solvent.

*2: When installing, be careful that grease applied to input shaft does not adhere to clutch disc.

Revision: 2005 September CL-6 C11

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Clutch Control System GCS000A1

Type of clutch control Hydraulic

B
Clutch Pedal GCS000A2

Pedal height 163 - 173 mm (6.42 - 6.81 in)

Pedal free play [Looseness at clutch pedal pin] 2 - 8 mm (0.08 - 0.31 in) [0 - 1.3 mm (0 - 0.051 in)] CL
Pedal height at clutch disengagement 82 mm (3.23 in) or more
Clearance ″C″ between pedal stopper rubber and clutch switch
0.74 - 1.96 mm (0.0291 - 0.0772 in) D
threaded while clutch pedal is fully depressed.

Clutch Disc GCS000A3

E
Model 200
Facing size (outer dia. × inner dia. × thickness) 200 mm × 140 mm × 3.5 mm (7.87 in × 5.51 in × 0.138 in)
Thickness of disc assembly with load 7.1 - 7.5 mm (0.280 - 0.295 in) with 4,658 N (475 kg, 1,047 lb) F
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 190 mm (7.48 in) dia.
Maximum spline backlash (at outer edge of disc) 0.8 mm (0.031 in)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in) G

Clutch Cover GCS000A4

Set-load 4,658 N (475 kg, 1,047 lb)

H

Diaphragm spring lever height 29 - 31 mm (1.14 - 1.22 in)

Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less
I

Revision: 2005 September CL-7 C11

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2005 September CL-8 C11