Component Tests and General Diagnostics

NOTICE: The clutch hydraulic system is to be serviced as a complete unit, it is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap.

1. Measure fork travel through access hole. Using a caliper, measure the travel of the fork with the clutch pedal in the full up position and then in the full down position. Subtract the full down position reading from the full up reading. This is the clutch fork travel. An alternative method is to use a piece of round wire rod and mark the up and down position on the rod and then measure the distance. If fork travel is below 11.18 mm (0.44 in.) travel is insufficient.
2. If fork travel is less than 11.18 mm (0.44 in.), check the following:
a. Fluid leaks in hydraulic system.
b. Damage to front of dash.
c. Damaged master/slave cylinder.
d. Air in system.
e. Master/slave cylinder improperly installed.

IMPORTANT: a, b, and d require clutch hydraulic system replacement.





3. Measure pedal travel. Pedal travel should be 135 mm -156 mm (5.3 - 6.2 in.).
If pedal travel is insufficient, check for:
a. Carpet or floor mat under pedal.
b. Faulty bushing/damaged pedal.
4. If fork travel and pedal travel are ok and clutch hydraulics are functioning properly, check for:
a. Bent fork.
b. Damaged pressure plate.