Clutch Pedal Assembly: Service and Repair

CLUTCH PEDAL REMOVAL/INSTALLATION [F35M-R]

CAUTION:
- Fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately.

- If clutch system-related hydraulic parts are removed, supply brake fluid, bleed air, and inspect for fluid leakage after the installation.

1. Disconnect the negative battery cable. Removal and Replacement

2. Remove the battery clamp and battery box and battery. Removal and Replacement

3. Remove in the order indicated in the table.

4. Plug the clutch pipe after removing it to avoid leakage.

5. Install in the reverse order of removal.

6. Fully depress the clutch pedal, and verify that the engine starts.










Reserve Hose Removal Note

1. Move the clip upward.






2. Disconnect the reserve hose.

Clutch Pipe Removal Note

CAUTION:
- When disconnecting the clutch pipe, the seal ring installed to the end of the clutch pipe connector may fall off or remain on the clutch pedal component clutch master cylinder side. If the clutch pipe is assembled with the seal ring not installed, it may cause fluid leakage from the clutch pipe connector or the clutch may not operate normally. When disconnecting the clutch pipe, remove the seal ring and clutch pipe connector as a single unit.

NOTE:
- A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that the clutch pipe is removed together with the seal ring when disconnecting the mid-connector.
- The O-ring type mid-connector seal ring is installed to the groove at the end of the clutch pipe.

1. Pull the clutch master cylinder clip to the position shown in the figure and pull out the clutch pipe connector straight to detach it.






2. Verify that the seal ring is removed together with the clutch pipe connector.






Starter Interlock Switch Installation Note

1. After installing the clutch pedal component, inspect the clutch pedal. Testing and Inspection

2. Insert the new starter interlock switch into the pedal bracket hole in the direction indicated by arrow A.






3. Slide the starter interlock switch pressing it in the direction indicated by arrow B until it is locked.






4. Fully depress the clutch pedal in the direction of arrow C, and verify that a click sound from the starter interlock switch is heard.

Clutch Pedal Position Switch Installation Note

1. Insert the new clutch pedal position switch into hole of the pedal bracket until the switch stops.

2. Rotate the clutch pedal position switch 45° clockwise.






3. Verify that the clutch pedal position switch is locked securely.

Clutch Pipe Installation Note

NOTE:
- A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that a seal ring is installed to the clutch pipe when connecting the mid-connector.
- The O-ring type mid-connector seal ring is installed to the groove at the end of the clutch pipe.

1. Verify that the seal ring is assembled to the clutch pipe so that the ends of the seal ring and the clutch pipe overlap each other.






CAUTION:
- Verify that there is no chipping or damage to the seal ring of the clutch pipe connector.

2. Return the clutch master cylinder clip to the position shown in the figure.






3. Insert the clutch pipe connector straight.

4. Pull the clutch pipe to verify that it does not come off, and reinsert it completely.

Reserve Hose Installation Note

1. Connect the reserve hose until a click is heard.






2. Verify that the reserve hose is securely installed by pulling it, and reinsert into the clutch master cylinder.

3. Add the clutch fluid, bleed the air, and inspect for leakage after the installation. Service and Repair