CLUTCH

SYSTEM
Return To Main Table of Contents
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CLUTCH PEDAL AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

 GENERAL

GENERAL
SPECIFICATIONS

Clutch operating method Cable type

Clutch disc
Type Single dry disc
Facing diameter (Outside x Inside) mm (in.) 184 x 127 (7.24 x 5.00)
Clutch cover assembly
Type Diaphragm spring strap drive type
Setting load N (lb.) 3050-3550 (686-798)

SERVICE STANDARD

Standard value
Clutch pedal height 178 mm (7 in.)
Clutch pedal free play 20-30 mm (0.8-1.2 in.)
Clutch pedal stroke 145 mm (5.7 in.)
Clearance between adjusting nut and cable holder 5-6 mm (0.20-0.24 in.)
Limit
Clutch disc
Revet sink 0.3 mm (0.012 in.)

TIGHTENING TORQUE Nm kg.cm Ib.ft

Transaxle to engine bolts 43-55 430-550 32-41

Starter motor mounting bolts 27-34 270-340 20-25
Clutch to flywheel 15-22 150-220 11-16

LUBRICANTS

Items Specified lubricants Quantity

Contact surface of release bearing MOLYWHITE TA No.2 As required

Inner surface of clutch release bearing MOLYWHITE TA No.2 As required
Inner surface of clutch disc spline MOLYWHITE TA No.2 As required
Clutch pedal shaft and bushings Chassis grease SAE J310, NLGI No.1 As required
Input shaft spline MOLYWHITE TA No.2 As required

41A-2
 GENERAL

SPECIAL TOOLS

Tool
Illustration Use
(Number and name)

09411-11000 Installation of clutch disc

Clutch disc guide

09414-24000 Removal of lock pin

Lock pin remover

41A-3
 GENERAL

TROUBLESHOOTING

Symptom Probable cause Remedy

Clutch chatter Worn or damaged disc assembly Replace disc assembly

Oil or grease on disc facings Replace disc assembly and correct

cause of contamination

Weak or broken disc damper springs Replace disc assembly

Broken or loose engine mounts Replace or tighten mounts

Clutch slipping Insufficient pedal free play Adjust clutch pedal free play

Burned, worn or oil soaked Replace disc assembly and correct

cause of contamination

Weak or broken pressure spring Replace cover assembly

Difficult gear shifting Excessive pedal free play Adjust clutch pedal free play

Worn or damaged disc assembly Replace clutch assembly

Clutch disc splines sticking Remove disc assembly and unstick

splines or replace disc

Clutch cable sticks Replace parts

Clutch cable broken or loose Repair or replace parts

Clutch noisy Clutch pedal bushing damaged Replace parts

Worn release bearing Replace release bearing

Worn disc assembly Replace disc assembly

Worn diaphragm spring Replace disc assembly

Clutch operation Insufficient lubrication on clutch Lubricate

erratic or rough pedal pivot

41A-4
 GENERAL

SERVICE ADJUSTMENT PROCEDURES

CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Measure the clutch pedal height (distance between upper
surface of floor board and top of clutch pedal) “A” as
illustrated.

Standard value (A) : 178 mm (7 in.)

NOTE:
The pedal height cannot be adjusted.

2. If the clutch pedal height is not within the standard value,

check the pedal stopper of the pedal support member for
deterioration.
3. Measure the clutch pedal free play “B”

Standard value (B) : 20-30 mm (0.8-1.2 in.)

4. If the clutch pedal free play is not within the standard value,
turn the outer cable adjusting nut at the bulkhead in the
engine compartment and adjust the clutch cable free play
(adjusting nut-to-insulator projection clearance) “C” to within
the following value.

Reference value (C) : 5-6 mm (0.20-0.25 in.)

5. After making the adjustment, depress the clutch pedal

several times and check that clutch pedal to floorboard
clearance “D” is within the standard value range when the
clutch is disengaged.

Standard value (D) : 33 mm (1.3 in.)

6. If the clutch pedal to floorboard clearance is less than the

standard value, a faulty clutch assembly is indicated. Repair
the clutch assembly.

41A-5
 CLUTCH PEDAL AND CABLE

CLUTCH PEDAL AND CABLE

COMPONENTS

Removal
1. Pull out the cable and turn the adjusting nut counter
clockwise to increase cable play.
2. Disconnect the cable from clutch lever.
3. Remove the clutch pedal.
4. Remove the cotter pin (Transaxle side).

41A-6
 CLUTCH PEDAL

INSPECTION
1. Inspect the dust boot for damage.
2. Test the cable for rough movement.
3. Inspect the outer cable for damage.
4. Check the condition of the connections at both ends of the
clutch cable.
5. Check the insulator for damage.

IGNITION LOCK SWITCH INSPECTION

1. Disconnect the connector.
2. Check to be sure that there is continuity between connector
terminals. (Refer to page 27-46 Ignition Lock System).

INSTALLATION
1. Apply the specified multi-purpose grease to the end of the
pedal as illustrated.

Specified grease : Multi-purpose grease SAE J310, NLGI

No.3 or equivalent
NOTE:
Adjust the clutch pedal height and the clutch pedal free
play.
Standard value:
Clutch pedal height : 178 mm (7 in.)
Clutch pedal free play : 20-30 mm (0.8-1.2 in.)

41A-7
 CLUTCH COVER AND DISC

CLUTCH COVER AND DISC

COMPONENTS

REMOVAL
1. Drain the clutch fluid and transaxle gear oil.
2. Remove the transaxle assembly.
3. Insert the special tool (09411-11000) in the clutch disc. To
prevent the disc from falling.
4. Loosen the bolts which attach the clutch cover to the
flywheel in a star pattern. Loosen the bolts in succession,
one or two turns at a time, to avoid bending the cover flange.

NOTE:
DO NOT clean the clutch disc or release bearing with
cleaning solvent.

41A-8
 CLUTCH COVER AND DISC

5. Remove the return clip and clutch release bearing.

6. Insert the special tool (09414-24000) in the spring pin and
attach the round nut to the end of the tool.

7. While holding the shaft of the special tool (09414-24000)

rotate the sleeve with a wrench to force out the spring pin.

8. Remove the clutch release shaft, packings, return spring and

release fork.

INSPECTION
CLUTCH COVER ASSEMBLY
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the
limit.

Limit: 0.5 mm (0.02 in.)

2. Check the pressure plate surface for wear, cracks and color
change.
3. Check the rivets for looseness and replace the clutch cover
assembly if necessary.

CLUTCH DISC
1. Check the facing for loose rivets, uneven contact, deteri-
oration due to seizure, adhesion of oil or grease and replace
the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out
of specification.

Limit: 0.3 mm (0.012 in.)

3. Check for torsion spring play and damage and if defective,

replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch
disc. If the disc does not slide smoothly or if play is excessive,
replace the clutch disc and/or the input shaft.

41A-9
 CLUTCH COVER AND DISC

CLUTCH RELEASE BEARING

Caution
The release bearing is packed with grease. Do not use cleaning
solvent or oil.

1. Check the bearing for seizure, damage or abnormal noise.

Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are
worn abnormally.

CLUTCH RELEASE FORK

1. If there is abnormal wear at the point of contact with the
bearing, replace the release fork.

INSTALLATION
1. Apply multipurpose grease to the release fork shaft. Pack the
portions of the clutch housing which are indicated in the
illustration with multipurpose grease.

Grease: MOLYWHITE TA NO. 2

Caution
When installing the clutch, apply grease to each part, but
be careful not to apply excessive grease; it can cause
clutch slippage and shudder.
2. Align the holes in the release fork with those in the release
fork shaft, and drive new spring pins into the holes.

Caution:
1) Install the spring pins so that the slits cross the
centerline of the release fork shaft as shown.
2) Do not reuse the spring pins.

3. Apply multipurpose grease into the groove of the release

bearing.

Grease: MOLYWHITE TA NO. 2

41A-10
 CLUTCH COVER AND DISC

4. Apply multipurpose grease to the release bearing contact

surfaces of the clutch release fork.

Grease: MOLYWHITE NO. 2

5. Clean the surfaces of the flywheel and pressure plate

thoroughly with fine sandpaper or crocus cloth, and make
certain that all oil or grease has been removed.
6. Apply a small amount of multipurpose grease to the clutch
disc splines and input shaft splines.

Grease MOLYWHITE TA NO. 2

Caution
Do not apply more grease than necessary. Too much
grease could cause clutch slip or judder.

7. Using the special tool (09411-11000). install clutch disc to

flywheel. When installing the clutch disc, be sure that the
surface having the manufacturers stamp is towards the
pressure plate side.
8. Install the clutch cover assembly onto the flywheel and
install six (6) bolts through the clutch cover into the flywheel.
9. Diagonally tighten the bolts to 15 to 21 Nm (150 to 210
kg.cm, 11 to 15 Ib.ft).
Tighten the bolts, one or two turns at a time, in succession,
to avoid bending the cover flange.
10. Remove the special tool.
11. Install the transaxle. (Refer to GROUP 43-Manual
Transaxle Assembly.)
12. Adjust the clutch pedal free-play.

41A-11