CLUTCH
S Y S T E M

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

CLUTCH PEDAL AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . .

6

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

GENERAL

GENERAL

SPECIFICATIONS

Clutch operating method

Clutch disc

Type

Facing diameter (Outside x Inside) mm (in.)

Clutch cover assembly

Type

Setting load N (lb.)

Cable type

Single dry disc

184 x 127 (7.24 x 5.00)

Diaphragm spring strap drive type

3 0 5 0 - 3 5 5 0 ( 6 8 6 - 7 9 8 )

SERVICE STANDARD

Standard value

Clutch pedal height

Clutch pedal free play

Clutch pedal stroke

Clearance between adjusting nut and cable holder

Limit

Clutch disc

Revet sink

178 mm (7 in.)

20-30 mm (0.8-1.2 in.)

145 mm (5.7 in.)

5-6 mm (0.20-0.24 in.)

0.3 mm (0.012 in.)

TIGHTENING TORQUE

Nm

kg.cm

Ib.ft

Transaxle to engine bolts

4 3 - 5 5

4 3 0 - 5 5 0

3 2 - 4 1

Starter motor mounting bolts

2 7 - 3 4

2 7 0 - 3 4 0

2 0 - 2 5

Clutch to flywheel

1 5 - 2 2

1 5 0 - 2 2 0

1 1 - 1 6

LUBRICANTS

Items

Specified lubricants

Quantity

Contact surface of release bearing

Inner surface of clutch release bearing

Inner surface of clutch disc spline

Clutch pedal shaft and bushings

Input shaft spline

MOLYWHITE TA No.2

MOLYWHITE TA No.2

MOLYWHITE TA No.2

Chassis grease SAE J310, NLGI No.1

MOLYWHITE TA No.2

As required

As required

As required

As required

As required

4 1 A - 2

GENERAL

SPECIAL TOOLS

Tool

(Number and name)

0 9 4 1 1 - 1 1 0 0 0

Clutch disc guide

Illustration

Use

Installation of clutch disc

0 9 4 1 4 - 2 4 0 0 0

Lock pin remover

Removal of lock pin

4 1 A - 3

GENERAL

TROUBLESHOOTING

Symptom

Clutch chatter

Clutch slipping

Difficult gear shifting

Clutch noisy

Clutch operation

erratic or rough

Probable cause

Worn or damaged disc assembly

Oil or grease on disc facings

Weak or broken disc damper springs

Broken or loose engine mounts

Insufficient pedal free play

Burned, worn or oil soaked

Weak or broken pressure spring

Excessive pedal free play

Worn or damaged disc assembly

Clutch disc splines sticking

Clutch cable sticks

Clutch cable broken or loose

Clutch pedal bushing damaged

Worn release bearing

Worn disc assembly

Worn diaphragm spring

Insufficient lubrication on clutch

pedal pivot

Remedy

Replace disc assembly

Replace disc assembly and correct

cause of contamination

Replace disc assembly

Replace or tighten mounts

Adjust clutch pedal free play

Replace disc assembly and correct

cause of contamination

Replace cover assembly

Adjust clutch pedal free play

Replace clutch assembly

Remove disc assembly and unstick

splines or replace disc

Replace parts

Repair or replace parts

Replace parts

Replace release bearing

Replace disc assembly

Replace disc assembly

Lubricate

4 1 A - 4

GENERAL

SERVICE ADJUSTMENT PROCEDURES

CLUTCH PEDAL INSPECTION AND

ADJUSTMENT

1. Measure the clutch pedal height (distance between upper

surface of floor board and top of clutch pedal) “A” as

illustrated.

Standard value (A) : 178 mm (7 in.)

NOTE:

The pedal height cannot be adjusted.

2.

If the clutch pedal height is not within the standard value,

check the pedal stopper of the pedal support member for

deterioration.

3. Measure the clutch pedal free play “B”

Standard value (B) : 20-30 mm (0.8-1.2 in.)

4.

If the clutch pedal free play is not within the standard value,

turn the outer cable adjusting nut at the bulkhead in the

engine compartment and adjust the clutch cable free play

(adjusting nut-to-insulator projection clearance) “C” to within

the following value.

Reference value (C) : 5-6 mm (0.20-0.25 in.)

5. After making the adjustment, depress the clutch pedal

several times and check that clutch pedal to floorboard

clearance “D” is within the standard value range when the

clutch is disengaged.

Standard value (D) : 33 mm (1.3 in.)

6. If the clutch pedal to floorboard clearance is less than the

standard value, a faulty clutch assembly is indicated. Repair

the clutch assembly.

4 1 A - 5

CLUTCH PEDAL AND CABLE

C L U T C H P E D A L A N D C A B L E

COMPONENTS

Removal

1. Pull out the cable and turn the adjusting nut counter

clockwise to increase cable play.

2. Disconnect the cable from clutch lever.

3. Remove the clutch pedal.

4. Remove the cotter pin (Transaxle side).

4 1 A - 6

CLUTCH PEDAL

INSPECTION

1. Inspect the dust boot for damage.

2. Test the cable for rough movement.

3. Inspect the outer cable for damage.

4.

Check the condition of the connections at both ends of the

clutch cable.

5. Check the insulator for damage.

IGNITION LOCK SWITCH INSPECTION

1. Disconnect the connector.

2.

Check to be sure that there is continuity between connector

terminals. (Refer to page 27-46 Ignition Lock System).

INSTALLATION

1. Apply the specified multi-purpose grease to the end of the

pedal as illustrated.

Specified grease : Multi-purpose grease SAE J310, NLGI

No.3 or equivalent

NOTE:

Adjust the clutch pedal height and the clutch pedal free

play.

Standard value:

Clutch pedal height : 178 mm (7 in.)

Clutch pedal free play : 20-30 mm (0.8-1.2 in.)

4 1 A - 7

CLUTCH COVER AND DISC

C L U T C H C O V E R A N D D I S C

COMPONENTS

REMOVAL

1. Drain the clutch fluid and transaxle gear oil.

2. Remove the transaxle assembly.

3.

Insert the special tool (09411-11000) in the clutch disc. To

prevent the disc from falling.

4. Loosen the bolts which attach the clutch cover to the

flywheel in a star pattern. Loosen the bolts in succession,

one or two turns at a time, to avoid bending the cover flange.

NOTE:

DO NOT clean the clutch disc or release bearing with

cleaning solvent.

4 1 A - 8

CLUTCH COVER AND DISC

5. Remove the return clip and clutch release bearing.

6.

Insert the special tool (09414-24000) in the spring pin and

attach the round nut to the end of the tool.

7. While holding the shaft of the special tool (09414-24000)

rotate the sleeve with a wrench to force out the spring pin.

8.

Remove the clutch release shaft, packings, return spring and

release fork.

INSPECTION

CLUTCH COVER ASSEMBLY

1.

Check the diaphragm spring end for wear and uneven height.

Replace if wear is evident or height difference exceeds the

limit.

Limit: 0.5 mm (0.02 in.)

2.

Check the pressure plate surface for wear, cracks and color

change.

3.

Check the rivets for looseness and replace the clutch cover

assembly if necessary.

CLUTCH DISC

1. Check the facing for loose rivets, uneven contact, deteri-

oration due to seizure, adhesion of oil or grease and replace

the clutch disc if defective.

2.

Measure the rivet sink and replace the clutch disc if it is out

of specification.

Limit: 0.3 mm (0.012 in.)

3. Check for torsion spring play and damage and if defective,

replace the clutch disc.

4. Clean the splines on the input shaft and install the clutch

disc. If the disc does not slide smoothly or if play is excessive,

replace the clutch disc and/or the input shaft.

4 1 A - 9

CLUTCH COVER AND DISC

CLUTCH RELEASE BEARING

Caution

The release bearing is packed with grease. Do not use cleaning

solvent or oil.

1. Check the bearing for seizure, damage or abnormal noise.

Also check the diaphragm spring contacting points for wear.

2.

Replace the bearing if the release fork contacting points are

worn abnormally.

CLUTCH RELEASE FORK

1. If there is abnormal wear at the point of contact with the

bearing, replace the release fork.

INSTALLATION

1.

Apply multipurpose grease to the release fork shaft. Pack the

portions of the clutch housing which are indicated in the

illustration with multipurpose grease.

Grease: MOLYWHITE TA NO. 2

Caution

When installing the clutch, apply grease to each part, but

be careful not to apply excessive grease; it can cause

clutch slippage and shudder.

2.

Align the holes in the release fork with those in the release

fork shaft, and drive new spring pins into the holes.

Caution:

1) Install the spring pins so that the slits cross the

centerline of the release fork shaft as shown.

2) Do not reuse the spring pins.

3. Apply multipurpose grease into the groove of the release

bearing.

Grease: MOLYWHITE TA NO. 2

4 1 A - 1 0

CLUTCH COVER AND DISC

4.

5.

6.

7.

8.

9.

Apply multipurpose grease to the release bearing contact

surfaces of the clutch release fork.

Grease: MOLYWHITE NO. 2

Clean the surfaces of the flywheel and pressure plate

thoroughly with fine sandpaper or crocus cloth, and make

certain that all oil or grease has been removed.

Apply a small amount of multipurpose grease to the clutch

disc splines and input shaft splines.

Grease MOLYWHITE TA NO. 2

Caution

Do not apply more grease than necessary. Too much

grease could cause clutch slip or judder.

Using the special tool (09411-11000). install clutch disc to

flywheel. When installing the clutch disc, be sure that the

surface having the manufacturers stamp is towards the

pressure plate side.

Install the clutch cover assembly onto the flywheel and

install six (6) bolts through the clutch cover into the flywheel.

Diagonally tighten the bolts to 15 to 21 Nm (150 to 210

kg.cm, 11 to 15 Ib.ft).

Tighten the bolts, one or two turns at a time, in succession,

to avoid bending the cover flange.

10. Remove the special tool.

11. Install the transaxle. (Refer to GROUP 43-Manual

Transaxle Assembly.)

12. Adjust the clutch pedal free-play.

4 1 A - 1 1