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CLUTCH
SECTION CL
CONTENTS
PRECAUTIONS ...............................................................2 Installation..................................................................16
Precautions ..................................................................2
PREPARATION ...............................................................3 RS5F70A
Special Service Tools ..................................................3
Commercial Service Tools ...........................................3 CLUTCH RELEASE MECHANISM ...............................17
NOISE, VIBRATION AND HARSHNESS (NVH) Components...............................................................17
TROUBLESHOOTING .....................................................4 Removal.....................................................................17
NVH Troubleshooting Chart.........................................4 Inspection...................................................................17
CLUTCH ...................................................................4 Installation..................................................................17
CLUTCH SYSTEM...........................................................5
Components - RHD Model with QG Engine - .............5 RS5F50A
Components - LHD Model with QG Engine -..............6
CLUTCH RELEASE MECHANISM ...............................20
Components - RHD Model with YD Engine -..............7
Components...............................................................20
Components - LHD Model with YD Engine - ..............8
Removal.....................................................................20
Inspection and Adjustment ..........................................9
Inspection...................................................................20
CLUTCH PEDAL INSPECTION ...................................9
Installation..................................................................20
CLUTCH PEDAL ADJUSTMENT ...............................10
AIR BLEEDING PROCEDURE ..................................10
CLUTCH MASTER CYLINDER.....................................11
CLUTCH DISC, CLUTCH COVER AND
Components...............................................................11
FLYWHEEL....................................................................22
Removal.....................................................................12
Components...............................................................22
Installation..................................................................12
Inspection and Adjustment ........................................22
Disassembly...............................................................12
CLUTCH DISC.........................................................22
Inspection...................................................................12
CLUTCH COVER .....................................................23
Assembly ...................................................................13 FLYWHEEL .............................................................23
OPERATING CYLINDER...............................................14 Installation..................................................................23
Components...............................................................14 SERVICE DATA AND SPECIFICATIONS (SDS) .........24
Removal.....................................................................14 Clutch Control System...............................................24
Disassembly...............................................................14 Clutch Master Cylinder ..............................................24
Inspection...................................................................14 Clutch Operating Cylinder .........................................24
Assembly ...................................................................15 Clutch Disc.................................................................24
Installation..................................................................15 Clutch Cover ..............................................................24
PIPING ...........................................................................16 Clutch Pedal ..............................................................24
Removal.....................................................................16
PRECAUTIONS
Precautions
Precautions NLCL0001
+ Recommended fluid is brake fluid "DOT 4". Refer to
MA-20, "Fluid and Lubricants".
+ 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 and operating cylinder.
+ Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
SBR820BA
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
CL-2
PREPARATION
Special Service Tools
Special Service Tools NLCL0002
Tool number
Description
Tool name
GG94310000 Removing and installing clutch piping
Flare nut torque wrench a: 10 mm (0.39 in)
NT406
KV30101600 (New) Installing clutch cover and clutch disc
KV30101000 (Former) (F70A)
Clutch aligning bar a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)
NT645
ST20630000 Installing clutch cover and clutch disc
Clutch aligning bar (F50A)
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)
NT405
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm spring adjust- clutch cover
ing wrench a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
NT404
KV32101000 Removing and installing spring pin
Pin punch a: 4 mm (0.16 in) dia.
NT410
Commercial Service Tools NLCL0003
Tool name Description
1 Flare nut crowfoot Removing and installing clutch piping
2 Torque wrench a: 10 mm (0.39 in)
NT360
CL-3
CLUTCH
tion. If necessary, repair or replace these parts.
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
NVH Troubleshooting Chart
Symptom
(Possible cause)
SUSPECTED PARTS
Reference page
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
gage
Clutch does not disen-
Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
CLUTCH PEDAL (Free play out of adjustment) CL-10
1
1
CLUTCH LINE (Air in line) CL-10
2
1
MASTER CYLINDER PISTON CUP (Damaged) CL-11
3
2
NVH Troubleshooting Chart
OPERATING CYLINDER PISTON CUP (Damaged) CL-14
4
2
Refer to EM-49, "Removal and Installation" (QG engine model) and
ENGINE MOUNTING (Loose)
1
EM-218, "Removal and Installation" (YD engine model).
CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-17 (RS5F70A), CL-20 (RS5F50A)
1
CLUTCH DISC (Out of true) CL-22
5
CLUTCH DISC (Runout is excessive) CL-22
5
2
CLUTCH DISC (Lining broken) CL-22
5
CLUTCH DISC (Dirty or burned) CL-22
5
CLUTCH DISC (Oily) CL-22
5
2
2
CLUTCH DISC (Worn out) CL-22
2
2
CLUTCH DISC (Hardened) CL-22
2
CLUTCH DISC (Lack of spline grease) CL-22
5
DIAPHRAGM SPRING (Damaged) CL-23
6
3
DIAPHRAGM SPRING (Out of tip alignment) CL-23
6
2
NLCL0004S0101
PRESSURE PLATE (Distortion) CL-23
7
4
NLCL0004S01
NLCL0004
FLYWHEEL (Distortion) CL-23
5
CLUTCH SYSTEM
Components -- RHD Model with QG Engine --
Components -- RHD Model with QG Engine -- NLCL0041
NCL046
1. Clutch pedal bracket 9. Reservoir cap 17. Spacer
2. Pedal stopper bolt 10. Reservoir tank 18. Operating cylinder
3. Clutch pedal 11. Hose clamp 19. Clutch hose
4. Clevis pin 12. Hose 20. Clutch lever
5. Bush 13. Filter 21. Spring pin
6. Snap pin 14. Clutch disc 22. Release bearing
7. Clutch master cylinder 15. Clutch cover 23. Release bearing spring
8. Nipple 16. Withdrawal lever
CL-5
CLUTCH SYSTEM
Components -- LHD Model with QG Engine --
Components -- LHD Model with QG Engine -- NLCL0048
NCL047
1. Clutch pedal bracket 9. Reservoir cap 17. Spacer
2. Clevis pin 10. Reservoir tank 18. Operating cylinder
3. Bush 11. Hose clamp 19. Clutch hose
4. Snap pin 12. Hose 20. Clutch lever
5. Pedal stopper bolt 13. Filter 21. Spring pin
6. Clutch pedal 14. Clutch disc 22. Release bearing
7. Clutch master cylinder 15. Clutch cover 23. Release bearing spring
8. Nipple 16. Withdrawal lever
CL-6
CLUTCH SYSTEM
Components -- RHD Model with YD Engine --
Components -- RHD Model with YD Engine -- NLCL0005
NCL048
1. Clutch pedal bracket 9. Reservoir cap 16. Operating cylinder
2. Pedal stopper bolt 10. Reservoir tank 17. Clutch hose
3. Clutch pedal 11. Hose clamp 18. Clutch disc
4. Clevis pin 12. Hose 19. Clutch cover
5. Bush 13. Filter 20. Clutch hose connector
6. Snap pin 14. Air bleeder screw 21. Release bearing
7. Clutch master cylinder 15. Withdrawal lever 22. Washer
8. Nipple
CL-7
CLUTCH SYSTEM
Components -- LHD Model with YD Engine --
Components -- LHD Model with YD Engine -- NLCL0049
NCL049
1. Clutch pedal bracket 9. Reservoir cap 16. Operating cylinder
2. Clevis pin 10. Reservoir tank 17. Clutch hose
3. Bush 11. Hose clamp 18. Clutch disc
4. Snap pin 12. Hose 19. Clutch cover
5. Pedal stopper bolt 13. Filter 20. Clutch hose connector
6. Clutch pedal 14. Air bleeder screw 21. Release bearing
7. Clutch master cylinder 15. Withdrawal lever 22. Washer
8. Nipple
CL-8
CLUTCH SYSTEM
Inspection and Adjustment
Inspection and Adjustment NLCL0006
CLUTCH PEDAL INSPECTION NLCL0006S04
Pedal Stroke NLCL0006S0401
Check clutch pedal stroke by using a 1◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo