SECTION CL

CONTENTS
PRECAUTIONS ..................................................................................................................................
CL- 2
PREPARATION ..................................................................................................................................CL- 3
CLUTCH SYSTEM ............................................................................................................................. CL- 4
INSPECTION AND ADJUSTMENT .............................................................................................CL- 5
HYDRAULIC CLUTCH CONTROL .............................................................................................CL- 6
CLUTCH RELEASE MECHANISM ..................................................................................................CL-10
CLUTCH DISC AND CLUTCH COVER ......................................................................................... CL-12
SERVICE DATA AND SPECIFICATIONS (S.D.S.) .....................................................................CL-15
 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 disc, wipe it with a dust collector. Do
not use compressed air.
 PREPARATION

SPECIAL SERVICE TOOLS

*: Special tool or commercial equivalent

Tool number
Tool name 1- Description

Inspectingdiaphragm spring of clutch

ST20050010
Base plate cover

ST20050100
Distance piece
* % Inspecting diaphragm spring of clutch
cover

GG94310000' Removing and installing each clutch piping

Flare nut torque
wrench

ST20600000' Installing clutch cover and clutch disc

(KV30100100)
Clutch aligning bar

ST2005O24OC Adjusting unevenness of diaphragm spring

Diaphragm spring of clutch cover
adjusting wrench

COMMERCIAL SERVICE TOOL

Tool name

Wk: $2(0:1281 d k

Unit: mm {k)
 CLUTCH SYSTEM

Fulcrum in a- -
mw l w 1 6 -22 (1.6 - 1.2~12- 16)
Stopper bolt

Lock nut
Hr-it (q) 1 6 - 2 2 ( 1 . 6 - 2 . 2 , 1 2 - 1 6 )
(0.8 - 1.1.5.8-8.0)
\ Return spring
Clevis pin @ Snap pln
c'-
(1 Clutch pedal

operation
cylinder
@ : Apply lithium-based grease including molybdenum disulphide.
(q) : N.m (kg-m, ft-lb)
INSPECTION AND ADJUSTMENT

Adjusting Clutch Pedal

1. ~ d j u s pedal
t height with pedal atopper.
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.
Pedal free play "A":
- -
1.0 3.0 mm (0.039- 0.118 in)
Pedal free play means the following total measured at posi-
tion of pedal pad:
Play due to clevis pin and clevis pin hole in clutch pedal.
Play due to piston and push rod.

Bleeding Procedure
Carefully monitor fluid level at master cylinder during
bleeding operation.
1. Top up reservoir tank with recommended brake fluid.
2. Connect a transparent vinyl tube to air bleeder valve.
3. Fully depress clutch pedal several times.
4. With clutch pedal depressed, open bleeder valve to release
air.
5. Close bleeder valve.
6. Repeat steps 4 through 6 above until clear brake fluid
comes out of air bleeder valve. -.
--,
 HYDRAULIC CLUTCH CONTROL

Clutch Master Cylinder

Piston cup =@)

Return spring
1
7

r\\
Piston assembly

rn@J Rubbing surface to

push rod

[C1 1.5 - 2.9 (0.15 - 0.3.1.1 - 2.2)

Remove this stopper, when
removing piston and return spring. =@J
Contact surface to piston assembly

L ~ m e r cylinder securing nut

(qJ 8 - 1 1 (0.8- 1.1.5.8-8.0) @ : Apply rubber grease.
(qJ :Nn(kg-m.ft-lb)
SCL330

DISASSEMBLY AND ASSEMBLY

Push piston in cylinder body with screwdriver when remov-
ing and installing valve stopper.

Align groove of piston assembly and valve stopper portion '

when installing valve stopper.
Check direction of piston caps.
 HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder (Cont'd)
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.
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.

Clutch Operating Cylinder

i

Air bleeder screw

-
7 9 (0.7 - 0.9.5.1 - 6.5)

@ Rubbing surface
to piston assembly

@ : Apply rubber grease.

: N.rn(kgm,h-lb)
SCL331

INSPECTION
Check rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
Check piston with piston cup for wear or damage. Replace if
necessary.
Check dust cover for cracks, deformation or damage.
Replace if necessary.
 HYDRAULIC CLUTCH CONTROL

Clutch Booster
1

- -
8 - 12 (0.8 1.2 5.8 8.7)

[0) : N-rn (kg-rn, ft-lb)

SeL3aa
=
- -
INSPECTION
Hoses and connectors
Check condition of vacuum hoses and connections.
Check vacuum hoses and check valve for air tightness.

- -
Gawlim lngine Check valve
Install check valve properly paying attention to its direction.
To mmifofold

t
-
1
f a brake
boomr boo=

Died r@no

-
+
To manifold
bee-

=La7
 HYDRAULIC CLUTCH CONTROL
Clutch Booster (Cont'd)
When pressure is applied to the clutch booster side of
check valve and valve does not open, replace check valve
Engine side
with a new one.

Clutch booster side

SCLlPO
ADJUSTMENT
Output rod length:
Length "A"
-
1.30 1.55 mm (0.0512 - 0.0610 in)

If 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.

Input rod length:

Length "B"
130 mm (5.12 in)
 CLUTCH RELEASE MECHANISM

=@ : Apply lithium-basedgrease including molybdenum disulphide.

REMOVAL AND INSTALLATION

Install retainer spring and holder spring.

Remove release bearing.

Install release bearing with suitable drift.

 CLUTCH RELEASE MECHANISM

INSPECTION
8 Check release bearing to see that it rolls freely and is free
from noise, crack, pitting or wear. Replace if necessary.
8 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.

Pack this recess

 CLUTCH DISC AND CLUTCH COVER

Do not clean in solvent.

When installing,be careful that grease applied to
main drive shaft does not adhere to clutch disc.

Clutch cover securing bolt

( 2 2 - 3.0 kg*.
16 - 22 ft4b)

: Apply lithium-basedgrease including

molybdenum diiulphiie.
SCL206

Clutch Disc
INSPECTION
Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
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 disc):
1.1 mm (0.043 in)
Runout limit:
1.3 mm (0.051 in)
Backlash of spline
Distance of runout check point (from hub center)
132.5 mm (5.22 in)
a Check clutch disc for burns, discoloration or oil or grease
leakage. Replace if necessary.

INSTALLATION
Apply recommended grease to contact surface of spline
portion.
Too much lubricant might cause clutch disc facing damage.
 CLUTCH DISC AND CLUTCH COVER

Clutch Cover and Flywheel

INSPECTION
Set Tool and check height and unevenness of diaphragm
spring.
Diaphragm spring height " A :
- -
44 46 mm (1-73 1.81 in)
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.
a 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:
0.5 mrn (0.020 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):
TD42 engine model
0.15 mm (0.0059 in) or less
TB42 engine model
0.1 mm (0.004 in) or less

INSTALLATION
Use suitable wire when installing clutch cover.
CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel (Cont'd)
Insert Tool 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 clutch control Hydraulic Model 275TBL

mlh -.=
CLUTCH MASTER CYLINDER Fadq s h mm {in)
275x 180x35
WuterdC.x i n n e r d i x
Inner diameter mm (in) 15.87 (518) (10.83 x 7.09 x 0.138)
thick&

Thickness of disc assembly

7.8- 8.2 (0.307 - 0.32311
With load
5,394 (550, 12 13)
CLUTCH OPERATING CYLINDER mm (in)lN (kg, Ib)

Engine f042. TB42

Inner diameter mm (in) 38.05 13141 CLUTCH COVER

CLUTCH BOOGTER
Engim TWt ma Full load
TVps M16
--

~ m a r n d i t mm (in) I lt4.3 (4SOJ

Inspection and Adjustment

CLUTCH PEDAL CLUTCH DISC
Unit: mm Iln) Unit: mm (in)

Model nmsL

-1 free play "A" Wear limit of facing surface to rivet head 0.3 10.0121

*: Measured from surface of melt sheet to pedal pad Runout limh of fmlq 1.3 (0.051 )

Distance of runout check point

(fromthe hub center)
1- (5321
CLUTCH BOOSTER Maximum backlash of spline
(at outer edge of disc) 1.1 t w 1
Output rod length " A
lint 1 1.30- 1.55
(0.0512 - 0.05101

CLUTCH COVER
Unit: mm (in)

Uneven limit of diaphragm spring toe

44-46(1.73- 1.81)