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CLUTCH

SECTION CL
CONTENTS
PRECAUTIONS ...............................................................2 Installation..................................................................16
Precautions ..................................................................2
PREPARATION ...............................................................3 RS5F30A, 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 NJCL0001
+ Recommended fluid is brake fluid "DOT 4". Refer to
MA-16, "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 NJCL0002

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) (F30A and 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 NJCL0003

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

CLUTCH LINE (Air in line) CL-10
2

MASTER CYLINDER PISTON CUP (Damaged) CL-11
3

NVH Troubleshooting Chart
OPERATING CYLINDER PISTON CUP (Damaged) CL-14
4

Refer to EM-137, "Removal and Installation" (QG engine model) and
ENGINE MOUNTING (Loose)
1

EM-137, "Removal and Installation" (YD engine model).
CL-4

RELEASE BEARING (Worn, dirty or damaged) CL-17 (RS5F30A, RS5F70A), CL-20 (RS5F50A)
1

CLUTCH DISC (Out of true) CL-22
5

CLUTCH DISC (Runout is excessive) CL-22
5

CLUTCH DISC (Lining broken) CL-22
5

CLUTCH DISC (Dirty or burned) CL-22
5

CLUTCH DISC (Oily) CL-22
5

CLUTCH DISC (Worn out) CL-22
2

CLUTCH DISC (Hardened) CL-22
2

CLUTCH DISC (Lack of spline grease) CL-22
5

DIAPHRAGM SPRING (Damaged) CL-23
6

DIAPHRAGM SPRING (Out of tip alignment) CL-23
6

NJCL0004S0101
PRESSURE PLATE (Distortion) CL-23
7

NJCL0004S01

NJCL0004
FLYWHEEL (Distortion) CL-23
5
CLUTCH SYSTEM
Components -- RHD Model with QG Engine --

Components -- RHD Model with QG Engine -- NJCL0041

SCL843-A

1. Clutch pedal bracket 11. Bush 21. Clutch disc
2. Pedal stopper bolt 12. Snap pin 22. Clutch cover
3. Bush 13. Fulcrum pin 23. Withdrawal lever
4. Clutch pedal 14. Clutch master cylinder 24. Spacer
5. Bush 15. Nipple 25. Operating cylinder
6. Clevis pin 16. Reservoir cap 26. Clutch hose
7. Assist spring 17. Reservoir tank 27. Clutch lever
8. Return spring 18. Hose clamp 28. Spring pin
9. Bush 19. Hose 29. Release bearing
10. Stopper rubber 20. Washer 30. Release bearing spring

CL-5
CLUTCH SYSTEM
Components -- LHD Model with QG Engine --

Components -- LHD Model with QG Engine -- NJCL0048

SCL844

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. Washer 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 -- NJCL0005

SCL845-A

1. Clutch pedal bracket 11. Snap pin 20. Air bleeder screw
2. Pedal stopper bolt 12. Fulcrum pin 21. Withdrawal lever
3. Bush 13. Clutch master cylinder 22. Operating cylinder
4. Clutch pedal 14. Nipple 23. Clutch hose
5. Bush 15. Reservoir cap 24. Clutch disc
6. Clevis pin 16. Reservoir tank 25. Clutch cover
7. Assist spring 17. Hose clamp 26. Clutch hose connector
8. Bush 18. Hose 27. Release bearing
9. Stopper rubber 19. Washer 28. Washer
10. Bush

CL-7
CLUTCH SYSTEM
Components -- LHD Model with YD Engine --

Components -- LHD Model with YD Engine -- NJCL0049

SCL846

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. Washer 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 NJCL0006
CLUTCH PEDAL INSPECTION NJCL0006S03
Pedal Stroke NJCL0006S0301
Check clutch pedal stroke by using a 1

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