Clutch Freeplay

INSPECTION AND ADJUSTMENT

1. MECHANICAL CLUTCH TYPE

1. Inspect tree play of clutch pedal by operating pedal by hand.
If it is out of the specified value, adjust it by turning wing nut on engine side of clutch cable at release fork.




Tightening torque
Adjusting nut on release fork):
4.4 - 7.4 Nm
(0.45 - 0.75 kg-m, 3.3 - 5.4 ft.lb)

Standard free play:
At clutch pedal
10 - 20 mm (0.39 - 0.79 in)




Fork lever free play allowance:
2 - 4 mm (0.08 - 0.16 in)

2. Pedal-to-floor plate gap in disengaged position

1. With the engine idling, pull parking brake lever completely.
2. Slowly depress clutch pedal while moving shift lever into reverse.
3. Stop depressing clutch pedal when gearshifting is complete. With clutch pedal in this position, measure the distance between the upper side of pedal pad and the lower end of front panel intersection of front panel with floor). Check that the measured value is within the specified standard.

Standard:
80 mm 3.15 in) or more

3. Pedal height
Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface.

2. HYDRAULIC CLUTCH TYPE




1. Push the release fork to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not.
2. If the fluid level rises, pedal free play is correct.
3. If the fluid level does not rise, or the push rod cannot be retracted, adjust the clutch pedal.
4. Inspect the underside of master cylinder, clutch damper and operating cylinder for clutch system, hoses, piping and their couplings for fluid leaks.
If fluid leaks are found, correct them by retightening their fitting bolt and/or replacing their parts.
5. Check the fluid level using the scale on the outside of the clutch master cylinder tank. It the level is below "MIN", add clutch fluid to bring it up to "MAX".

Recommended clutch fluid:
FMVSS No.116, fresh DOT3 or DOT4 brake fluid






CAUTION:
- Avoid mixing different brakes of brake fluid to prevent degradation of the fluid.
- Be careful not to allow dirt or dust to get into the reservoir tank.
- Use fresh DOT3 or DOT4 brake fluid when refilling fluid.