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Clutch
General Steps ........................................... H1-1
Clutch Pipe Removal/Installation .... H1-1
Clutch Pedal ............................................. H1-1
Clutch Pedal Inspection/Adjustment ........
......................................................... H1-1
Clutch Master Cylinder ............................ H1-2
Clutch Master Cylinder Removal/
Installation ....................................... H1-2
Clutch Master Cylinder Disassembly/
Assembly ......................................... H1-3
Clutch Slave Cylinder .............................. H1-3
Clutch Slave Cylinder Removal/
Installation ....................................... H1-3
Clutch Slave Cylinder
Disassembly/Assembly .................... H1-4
Gearshift................................................... H1-5
Gearshift Removal/ Installation ....... H1-5
General Steps
H1-1
General Steps
Clutch Pipe Removal/Installation
Attention:
l Clutch and brake system share one
fluid reservoir.
1. If the clutch has been disassembled for
any purpose, please replenish brake fluid
and bleed air in it; check for oil leakage
after reinstallation.
2. Remove the clutch pipe with SST (49
0259 770B) double open-end wrench,
and install with torque rod and the tools
mentioned above.
3. Clutch flange nuts should be tightened to
the required torque (see the General Steps
- Torque Specifications)
Clutch Pedal
Clutch Pedal Inspection/Adjustment
1. Measure the distance between the clutch
pedal center and the carpet.
Pedal height
228—233mm (9.10—9.29in)
Clutch Pedal Free Travel
1. Measure clutch pedal free travel: Clutch
Pedal free travel is the distance when the
clutch pedal is pressed down manually
until resistance is felt.
Pedal free travel:
18.72—21.99mm (0.75—0.88in)
Clutch Pedal Separation Point
1. Engage parking brake and stick the front
and rear wheels with wooden blocks.
2. Start engine and run in idle.
3. Do no step on the clutch pedal; slowly
pull the shift lever to reverse gear
4. When gear noise is heard, keep the shift
lever in the very position.
5. Step on the clutch pedal slowly.
6. When the gear noise disappears, maintain
the clutch pedal height (clutch pedal
Separation Point).
7. Measure the clutch pedal separation
travel and total travel.
8. Confirm they are within the specified
range.
If they are out of range, adjust pedal
height or free travel to the specified
values.
Clutch pedal separation travel:
23-25mm (0.91—0.99in) (for reference)
Pedal free travel
Pedal height
A: TighteningTorques2~4.9Nm
Pedal free travel
Clutch Pedal
H1-2
Clutch pedal Total travel:
131mm (5.50in) (for reference)
Clutch Pedal Removal/Installation
1. Remove in order 1-2-3-4-5 as shown in
the diagram.
2. Install in reverse order 5-4-3-2-1 as of
removal.
3. When installed, adjust the clutch pedal
(see Clutch Pedal – Clutch Pedal
Inspection/Adjustment)
4. Plug up the oil pipe at the time of removal
to prevent oil leakage
Attention: Do not drip brake fluid on ABS
module.
1 Clutch switch
2 Self-Locking Nut
3 Self-Locking Nut
4 Self-Locking Nut
5 Clutch Pedal
Clutch Master Cylinder
Clutch Master Cylinder Removal/
Installation
1. Remove in order 1-2-3-4-5 as shown in
the diagram.
2. When oil pipe is removed, plug it
immediately to prevent oil leakage.
3. Install in reverse order 5-4-3-2-1 as of
removal.
1 Split Washer
2 Axis Pin
3 Self-Locking Nut
4 Self-Locking Nut
5 Fluid Reserve Pipe
Clutch Separation Point
Clutch Pedal Separation Travel
Clutch Pedal Total Travel
Tightening Torque:18N·m~28 N·m
Nominal Value 22 N·m
Clutch Master Cylinder
H1-3
Clutch Master Cylinder Disassembly/
Assembly
1. Remove in order 1-2-3-4-5 as shown in
the diagram.
2. Separate the piston split washer and
cylinder with slotted screwdriver in the
removal of piston assembly.
3. Install in reverse order as of removal.
1 Clip
2 Clip
3 Fluid Reserve Pipe
4 Split Washer
5 Piston
6 Bush
7 Return Spring
8 Gasket
9 Clutch Master Cylinder
Clutch Slave Cylinder
Clutch Slave Cylinder Removal/
Installation
1. Disassemble in order 1-2-3-4 as shown in
the diagram.
2. Install in reverse order 4-3-2-1 as of
removal.
1
Hexagon Flange Bolts
2
Hexagon Flange Bolts
3
Coupling Nut
4
Clutch Slave Cylinder
Tightening Torque:18N·m~28 N·m
Nominal Value 22 N·m
Tightening Torque:16N·m~21.75 N·m
Clutch Pedal
H1-4
Clutch Slave Cylinder Disassembly/Assembly
1. Disassemble in order 1-2-3-4-5-6-7-8 as shown in the diagram.
2. Install in reverse order 8-7-6-5-4-3-2-1 as of removal.
1 Dust Boot Fixed Block
2 Piston Assembly
3 Return Spring
4 Piston Stopper
5 Dust Cover
6 Bleed Screw Cap
7 Bleed Screw
8 Bush
Flywheel
H1-5
Gearshift
Gearshift Removal/ Installation
1. Remove with the sequence shown in the diagram.
2. Install in the reverse order of removal.
3. Verify the whether the gear shift runs smoothly after installation.
1 Shift Lever Handle
2 Control Cable
3 Gearshift
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