Professional Documents
Culture Documents
Section 18 - Clutch - Chapter 1
Section 18 - Clutch - Chapter 1
SECTION 18 – CLUTCH
Chapter 1 – Clutch
CONTENT
604.55.111.00 – 06 – 2002
2 SECTION 18 – CLUTCH – CHAPTER 1
TIGHTENING TORQUES
604.55.111.00 – 06 – 2002
SECTION 18 – CLUTCH – CHAPTER 1 3
G
D
A
B
Hydraulic clutch control assembly
A. Master Cylinder 5. Rod
B. Bottom hydraulic cylinder 6. Locknut
G = 0.1 to 1.4 mm. Rod clearance (5) with clutch pedal 7. Fork
released. 8. Bottom cylinder
D = 137.5 to 138 mm. Fork centre (7) distance from pump 9. Spring
body mounting plate 10. Piston
1. Pump body 11. Seal
2. Spring 12. Pin
3. Seal
4. Plunger
604.55.111.00 – 06 – 2002
4 SECTION 18 – CLUTCH – CHAPTER 1
TROUBLESHOOTING
(to be continued)
604.55.111.00 – 06 – 2002
SECTION 18 – CLUTCH – CHAPTER 1 5
TROUBLESHOOTING
Clutch grabs 1. Stiff external control linkage. Check and lubricate linkage pivot
points.
2. Warped clutch disc (9, page 3). Replace clutch disc.
3. Clutch disc (9) slides with Remove clutch and check
difficulty over clutch shaft. meshing. Replace faulty parts as
necessary.
4. Clutch disc (9) with damaged Replace clutch disc.
damper springs or loose at hub
(loose rivets).
5. Oil or grease on disc friction Replace clutch disc; repair leak of
material (9) . lubricant into clutch housing;
thoroughly clean friction surfaces.
6. Diaphragm spring (3) with Replace clutch.
broken elements.
Clutch fails to disconnect and 1. Warped clutch disc (9). Replace clutch disc.
drags
2. Seizure of external controls. Check and replace faulty items;
lubricate.
3. Hydraulic drive pump and/or Overhaul or replace pump and/or
bottom cylinder failure. cylinder.
4. Clutch disc (9) slides with Release disc and replace disc or
difficulty along the shaft. shaft, as necessary.
5. Control misadjustment. Adjust control (see page 15).
6. Air inside the clutch release Bleed hydraulic system (see page
hydraulic circuit. 18) and replace pump and/or
bottom cylinder seals, as
necessary.
7. Diaphragm spring (3) with Replace clutch and/or bearing.
broken elements and/or
damaged clutch release
bearing.
Clutch noise at engagement 1. Warped clutch disc (9). Replace disc.
and/or disengagement
2. Damaged clutch disc (9) Replace disc.
damper springs.
3. Excess backlash on clutch disc Replace disc and shaft, as
(9) to hub meshing splines. necessary.
Clutch noise at disengagement 1. Worn clutch release bearing Replace bearing.
Clutch control pedal hardness 1. Broken or disconnected clutch Replace or hook–up clutch return
return spring. spring.
2. Seized pump plunger. Overhaul or replace pump.
3. Stiff external control linkage. Check and lubricate linkage pivot
points.
4. Hard pedal. Check and lubricate linkage.
604.55.111.00 – 06 – 2002
6 SECTION 18 – CLUTCH – CHAPTER 1
CLUTCH
604.55.111.00 – 06 – 2002
SECTION 18 – CLUTCH – CHAPTER 1 7
2
Diagram for sealer application before mounting engine to transmission/clutch housing.
604.55.111.00 – 06 – 2002
8 SECTION 18 – CLUTCH – CHAPTER 1
1
4. Loosen retaining screws and remove the side
panel (1).
2
5. Remove retaining screws (1 and 2) and remove
protection from left side.
604.55.111.00 – 06 – 2002
SECTION 18 – CLUTCH – CHAPTER 1 9
4
8. Remove the split pin and slide out the pivot pin
(2). Loosen retaining screws (1) and withdraw
the clutch master cylinder from front side.
5
9. Unscrew the clutch release line (1), remove the
retaining screw (2) and nuts (4). Remove the
hydraulic cylinder (3).
10. Reinstallation of the clutch control assembly
follows the removal procedure in reverse. After
installation, carry out pedal adjustment as
described below.
6
Clutch pedal adjustment
11. Adjust distance (D, page 3) before reassembling
the control pump.
12. With the clutch pedal (1) connected to the fork
(2), check distance (H) from the middle of pedal
to the mat top. It should be approx. 190 mm.
604.55.111.00 – 06 – 2002
10 SECTION 18 – CLUTCH – CHAPTER 1
8
CLUTCH HYDRAULIC CONTROL ASSEMBLY
WARNING
Always use appropriate tools to align holes. NEVER
USE YOUR HANDS OR FINGERS. 1
Proceed as follows:
2
1. Put the master cylinder in a vice and slide the
tank (1) out of the body (2).
24433
1
2. Back off the rubber sleeve (2), remove circlip (3)
and withdraw the entire rod assembly (1)
completely.
1
24434
604.55.111.00 – 06 – 2002
SECTION 18 – CLUTCH – CHAPTER 1 11
24435
3
4. Place the bottom hydraulic cylinder (1) in a vice,
1 2 3
release the spring clip (2) and remove the sleeve
(3).
24436
4
5. Blow out the piston (1) and spring using
compressed air.
6. Reassemble the clutch control master cylinder
and bottom hydraulic cylinder taking into account 1
the following:
– Reassembly follows the disassembly
procedure in reverse, from step no. 5 back to
step no. 1;
– Check seals for proper condition and replace
them if necessary;
– Check sliding surfaces of the pistons and
bores.
24437
604.55.111.00 – 06 – 2002
12 SECTION 18 – CLUTCH – CHAPTER 1
1
4. Hold the clutch pedal down and unscrew the
bleeding screw (1) by half a turn. Let drain oil with
air bubbles.
5. Screw in the screw (1) and repeat the above
steps until oil free of air comes out.
6. Press again the clutch pedal to pressurise the
circuit. This condition exists when pedal
operation is felt normal again.
7. Upon completion of bleeding, top up oil in the
reservoir to correct level (1, fig. 1).
604.55.111.00 – 06 – 2002