Component Tests and General Diagnostics

INSPECTION





1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet: 162 - 172 mm (6.38 - 6.77 inch)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
a. Remove the lower finish panel.
b. Loosen the lock nut and clutch switch until the height is correct.
Tighten the lock nut.
Torque: 15.7 Nm (160 kgf-cm, 12 ft. lbs.)

HINT: Before rotating the clutch switch for pedal height adjustment, disconnect the clutch switch connector.

c. Install the lower finish panel.





3. CHECK THAT PEDAL FREE PLAY AND PUSH ROD PLAY ARE CORRECT
a. Depress the pedal until the clutch resistance begins to felt.
Pedal free play: 5.0 - 15.0 mm (0.197 - 0.591 inch)
b. Gently push on the pedal until the resistance begins to increase a little.
Push rod play at pedal top: 1.0 - 5.0 mm (0.039 - 0.197 inch)
4. IF NECESSARY, ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY
a. Loosen the lock nut and turn the push rod until the free play and push rod play are correct.
b. Tighten the lock nut.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
c. After adjusting the pedal free play, check the pedal height.





5. INSPECT FULL PEDAL STROKE
Full pedal stroke: 142.0 - 147.5 mm (5.591 - 5.807 inch)
6. INSPECT CLUTCH RELEASE POINT
a. Pull the parking brake lever and install wheel stopper.
b. Start the engine and idle the engine.
c. Without depressing the clutch pedal, slowly shift the shift lever into the reverse position until the gears contact.
d. Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 inch) or more (From pedal stroke end position to release point)
If the distance is not as specified, do the following operation.
- Inspect pedal height.
- Inspect push rod play and pedal free play.
- Bleed the clutch line.
- Inspect the clutch cover and disc.





7. CHECK CLUTCH START SYSTEM
a. Check that the engine does not start when the clutch pedal is released.
b. Check that the engine starts when the clutch pedal is fully depressed.
If necessary, replace the clutch start switch.





8. INSPECT CONTINUITY OF CLUTCH START SWITCH
a. Check that there is continuity between the terminals when the switch is ON (pushed).
b. Check that there is no continuity between the terminals when the switch is OFF (free).
If continuity is not as specified, replace the switch.