Chassis

 Clutch
 M5S-C9 Manual Transmission
 Propeller Shaft
 Rear Differential
 Rear Axle
 Suspension
 Brake
 Steering System
 Spare Tire
Chassis
 Clutch
• General
– A dry type single plate clutch
which is operated by cable is used
Dry Type Single-Plate Clutch
Type
Clutch Diaphragm Spring
Operation Mechanical (cable)
Type DST *1

Clutch
Size (mm) 190
Cover
Installed load (N) 3550
Facing size *2
(mm)
Clutch 190 x 132 x 3.5
Disc
Facing area (cm2) 146.7
Clutch Pedal Conventional
*1 : DST (Diaphragm Spring Turnover)
*2 : Outer Diameter x Inner Diameter x Thickness
Chassis
 Clutch
• General
– Clutch system requires inspection and adjustment
of the pedal free play every 1 year or 10,000 km
Clutch Adjust Nut
Cable
Clutch
Pedal

Grommet
Chassis
 Clutch
• Adjustment
– Clutch pedal free play adjustment
1, Pull the clutch outer cable until 2, Turn the adjusting nut until
the clutch release bearing it is about 3 - 6 mm from
contacts the diaphragm spring the grommet
of the clutch cover
3 - 6 mm
(force to pull: about 20 - 40 N)

Next
20 - 40 N
Chassis
 Clutch
• Adjustment
– Clutch pedal free play adjustment
3, Set the groove of the adjusting 4, Check that the clutch pedal
nut to the grommet protrusion free play is with the standard
(15 - 20 mm)
Grommet
Protrusion

15 - 20 mm
Chassis
 M5S-C9 Manual Transmission
• General
– M5S-C9 5-speed manual transmission for K3-DE
Transmission Type M5S-C9
1st 3.769
2nd 2.045

Gear 3rd 1.376

Ratio 4th 1.000
5th 0.838
Reverse 4.128
Oil capacity (Liters) 1.2
Oil Viscosity SAE 75W-90
Oil grade API GL-4
Dry Weight (Kg) 23.2
Chassis
 M5S-C9 Manual Transmission

Filler
Plug

Drain
Plug

Mass Damper
Chassis
 M5S-C9 Manual Transmission
• Shift Lever
– Service point for shift lever shaft removal
Chassis
 M5S-C9 Manual Transmission
• Shift Lever
– Service point for shift lever
shaft removal

ONLY

Taper Pin
SST (09031-00040)
Chassis
 M5S-C9 Manual Transmission
• Lubrication Mechanism
– Oil Slinger is provided for lubrication inside the
extension housing

Oil Slinger Oil Guide Plate

Extension Housing
Bushing

Oil Slinger
Chassis
 M5S-C9 Manual Transmission
• Lubrication Mechanism

Dust Collector
(Magnet)

Oil Slinger
Chassis
 M5S-C9 Manual Transmission
• Sub Gear
– Sub gear are provided on 1st and 2nd counter
gear for noise reduction

Sub Gear
No. 2

Counter
Gear No. 2

Counter
Gear No. 1

Spring
Sub Gear
No. 1
Chassis
 M5S-C9 Manual Transmission
• Reverse One-Way Mechanism
– The reverse one-way mechanism operates the
reverse shift arm only when the reverse shift
head is moved towards the reverse gear side
Reverse Reverse
5th
Shift Head

Pin

Reverse
Shift Arm

Reverse
Idler gear

Reverse Shift
Arm Bracket
Chassis
 M5S-C9 Manual Transmission Reverse
Shift Arm
• Reverse One-Way Mechanism
Pin
Reverse Neutral 5th

Reverse Reverse Pin Reverse shift arm is

Gear Shift Arm not moved
Chassis
 Propeller Shaft
• Description
– 3-joint type with center bearing

Center
Bearing
Chassis
 Rear Differential
• General

Specifications

Gear Ratio 5.125

Ring Gear Size

180
(mm)
Oil Capacity
1.6
(Liter)

Oil Viscosity SAE80W-90

Oil Grade API GL-5

Oil Type Hypoid

Chassis Breather Plug
 Rear Differential
• General

Magnet

Drain Plug
Chassis
 Rear Axle
• General

Rear Right Rear Left

Axle Axle

Bearing, pressed
fit to rear axle
Chassis
 Suspension
• General

MacPherson strut
type independent
suspension

4 link coil spring with the

lateral rod type rigid axle
suspension
Chassis
 Brake
Lever type
• General PKB

9 in. Single
Booster

P&B
Valve

Leading-
Trailing Drum

Solid Disc
(for 13 in.)
Chassis
 Brake
• General

Rear Left Rear Right

Chassis
 Steering System
• General
– Power steering with
energy absorbing
mechanism
Intermediate Shaft

Steering Column

Serration Portion

Resin Pin
Primary
Collision

Primary
Collision
Chassis
 Steering System
• General
– Energy absorbing mechanism
Upper Bracket Slide Plate
Lower Tube

Upper
Contract Tube

Secondary
Collision
Chassis
 Spare Tire Lock Bolt