Page 473 of 513

CLUTCH
2
Measuring
and
adjusting
height
of
diaphragm
spring
I
Line
up
distance
piece
special
tool
ST20059001
on
clutch
assembly
base
plate
special
tool
ST20101O
0
ST20059001
I
ST20101000
Fig
CL
5
Base
plate
and
distance
piece
2
Place
the
clutch
assembly
on
the
distance
piece
and
set
the
clutch
assembly
on
the
base
plate
stationarily
Under
this
condition
the
distance
piece
is
placed
beneath
the
pressure
plate
3
Measure
the
diaphragm
spring
height
from
the
upper
surface
of
the
base
plate
with
vernier
caliper
depth
gauge
Height
of
diaphragm
spring
end
29
0
to
31
mm
1
142
to
1
220
in
at
diameter
62
mm
2
441
in
29
0
to
31
It
142
to
1
2201
6212
44
t
r
1
G
L
ir
I
LJIlW
I
y
y
x
l
i
0
BASE
PLATE
Unit
mm
in
Fig
CL
6
Measuring
height
of
dio
phTagm
spTing
4
Adjust
height
of
the
diaphragm
spring
by
the
use
of
diaphragm
spring
adjusting
wrench
special
tool
ST20
1
05000
if
required
Fig
CL
7
Adjusting
dio
phTagm
spring
height
Disc
assembly
If
the
facing
is
soiled
with
grease
or
oil
clean
off
with
gasoline
tetracWoride
and
dress
the
facing
with
a
wire
brush
Replace
the
facing
if
required
2
Check
the
disc
for
deflection
and
repair
or
replace
if
the
deflection
at
the
outer
circumference
of
the
facing
exceeds
the
following
value
Upper
limit
of
the
deflection
0
5
mm
0
0197
in
at
85
mm
3
3460
in
radius
Unit
mm
in
Fig
CL
8
Checking
disc
fOT
deflection
CL
3
Page 474 of 513

CHASSIS
Replace
the
disc
assembly
if
the
facing
is
worn
to
such
an
extent
that
the
facing
height
above
rivet
is
less
than
0
3
mm
0
0118
in
the
facing
is
worn
unevenly
or
rivets
are
loose
Depth
9au@e
II
i
I
I
il
S
I
I
F
d
I
id
Above
0
3
10
0118
Unit
mm
in
Fig
CL
9
Checking
clutch
facing
for
wear
Release
bearing
and
sleeve
When
withdrawal
lever
and
bearing
sleeve
contact
pomt
is
worn
in
step
replace
the
sleeve
2
When
grease
leaks
from
the
release
bearing
or
noise
occurs
on
the
release
bearing
replace
the
release
bearing
Fig
CL
J
0
Fittitlg
release
bearir
g
REASSEMBLY
Release
mechanism
Tightly
fit
the
release
bearing
to
the
placc
on
the
bearing
sleeve
as
shown
in
Figure
CL
10
When
the
hearing
is
installed
completely
turn
the
bearing
with
a
finger
and
make
sure
that
the
bearing
operates
smoothly
2
Apply
multi
purpose
grease
to
the
following
places
Bearing
sleeve
inside
groove
l
Pack
this
recess
I
1
II
J
Fig
CL
11
Lubricated
position
m
the
bearing
sleeve
Withdrawal
lever
and
bearing
sleeve
contact
point
Withdrawal
lever
ball
pin
and
withdrawal
lever
contact
surface
I
I
1
Withdrawal
ball
pin
I
2
Withdrawal
lever
Fig
CL
12
Position
on
the
withdrawal
lever
to
which
grease
is
applied
3
When
grease
is
applied
to
the
necessary
places
install
the
withdrawal
lever
release
bearing
and
bearing
sleeve
un
the
clukh
housing
connect
them
with
return
spring
and
install
the
dust
cover
on
the
clutch
housing
CL
4
Page 475 of 513

CLUTCH
J
I
I
Withdrawal
lever
2
Return
spring
I
31
Release
bearing
ST20610000
iwn
rm
hj
sf
W
Fig
CL
13
Installing
release
mechanism
REINSTALLATION
L
Clean
the
clutch
pilot
bushing
and
fill
it
with
multi
purpose
grease
2
Install
the
disc
assembly
and
clutch
assembly
on
the
flywheel
by
the
use
of
a
special
tool
clutch
aligning
bar
ST206
I
0000
12
I
Flywheel
Clutch
assembly
131
Clutch
disc
assembly
Fig
CL
14
Installing
disc
and
clutch
assembly
CLUTCH
CONTROL
CONTENTS
DESCRIPTION
CL
5
Removal
CL
9
CLUTCH
PEDAL
Hydraulic
clutch
CL
6
Disassembly
CL
9
Removal
CL
6
Inspection
CL
9
Inspection
CL
6
Reassembly
CL
9
Reinstallation
CL
6
Reinstallation
CL
10
Adjustment
CL
6
OPERATING
CYLINDER
Hydraulic
clutch
CL
10
CLUTCH
PEDAL
CLUTCH
CONTROL
Removal
CL
10
CABLE
Mechanical
clutch
CL
7
Disassembly
CL
10
Removal
CL
7
Inspection
CL
10
Inspection
CL
7
Reassembly
CL
10
Reinstallation
CL
7
Reinstallation
CL
10
Adjustment
CL
7
ADJUSTING
WITHDRAWAL
LEVER
CL
10
CLUTCH
MASTER
CYLINDER
BLEEDING
CLUTCH
SYSTEM
Hydraulic
clutch
CL
9
Hydraulic
clutch
CL
11
DESCRIPTION
The
B
I
IO
series
vehicles
with
left
hand
steering
wheel
and
right
hand
steering
wheel
respectively
adopt
hydraulic
type
and
mechanical
type
clutch
control
systems
The
hydraulic
type
clutch
control
system
consists
of
pendent
clutch
pedal
master
cylinder
operating
cylinder
and
withdrawal
lever
The
withdrawal
lever
is
of
an
inner
CL
5
Page 476 of 513

CHASSIS
fulcrum
type
The
mechanical
type
clutch
control
system
consists
of
pendent
clutch
pedal
clutch
control
cable
and
with
drawallever
The
withdrawal
lever
is
of
an
outer
fulcrum
type
which
provides
a
great
lever
ratio
and
thus
force
required
in
depressing
clutch
pedal
is
reduced
CLUTCH
PEDAL
Hydraulic
clutch
Removal
Remove
the
return
spring
2
Loosen
the
lock
nut
of
the
master
cylinder
push
rod
and
disconnect
the
push
rod
end
3
Remove
the
lock
nut
and
washer
of
the
pedal
shaft
and
remove
the
pedal
lever
Inspection
Thoroughly
clean
all
disassembled
parts
indicated
below
and
carefully
check
them
for
wear
damage
and
other
abnormal
conditions
Repair
or
replace
them
with
new
ones
if
required
f
fS
C5
J
dJ
YII
10
1
@
c
i
@
j
1
4
K
Clutch
pedal
free
trrlel
30
mm
1
181
nl
00
@
P
IO
Pedal
head
rubber
2
Return
spring
3
Pedal
lever
bush
4
Fulcrum
pedal
pin
etc
Reinstallation
Reinstall
the
clutch
pedal
in
reverse
sequence
of
removal
Adjustment
I
Adjust
pedal
pad
height
to
143
5
mm
5
65
in
without
stopper
The
adjustment
is
made
by
selecting
and
applying
shim
s
having
adequate
thickness
Be
sure
to
use
shims
having
same
thickness
for
both
upper
and
lower
2
Next
adjust
the
pedal
stopper
properly
so
that
the
pedal
pad
height
is
141
5
mm
5
57
in
and
secure
the
position
with
lock
nut
Note
Make
sure
that
chassis
grease
has
been
applied
to
the
leG
marked
portions
two
places
Grease
if
required
Adjusting
shim
Part
number
Thickness
mm
in
30611
27260
30612
27260
30613
27260
1
6
0
0630
0
8
0
0315
0
5
0
0197
I
2
3
Adjusting
shim
Pedal
lever
Pedal
stopper
Unit
mm
inl
Fig
CL
J5
Pedal
height
adjustment
CL
6
Page 477 of 513

CLUTCH
CLUTCH
PEDAL
AND
CLUTCH
CONTROL
CABLE
Mechanical
clutch
Removal
Loosen
the
control
cable
adjusting
nut
and
discon
nect
the
control
cable
from
the
withdrawal
lever
III
Adjusting
nut
2
I
Lock
nut
Fig
CL
16
Clutch
cunITol
cable
11
I
Withdrawal
lever
I
2
I
Clutch
control
cable
Fig
CL
17
Disconnecting
clutch
control
cable
2
Unhook
the
clutch
pedal
return
spring
3
Remove
the
clutch
brake
Pedal
installation
bolts
and
remove
the
clutch
pedal
and
control
cable
1
I
Return
spring
31
au
tch
pedal
2
Fulcrum
pedal
pin
Fig
CL
I8
Removing
pedal
installation
bolt
Inspection
Thoroughly
clean
all
disassembled
parts
indicated
below
and
carefully
check
them
for
wear
damage
and
other
abnormal
conditions
Repair
or
replace
as
required
Control
cable
2
Pedal
head
rubber
3
Pedal
lever
bush
4
Fulcrum
pedal
pin
5
Others
Reinstallation
Reinstall
the
clutch
pedal
and
clutch
control
cable
in
reverse
sequence
of
removal
Alljustment
Adjust
the
pedal
stopper
so
that
pedal
height
is
in
range
from
136
5
to
146
5
mm
5
4
to
5
8
in
and
secure
the
position
with
lock
nut
completely
2
Next
adjust
the
control
cable
adjust
nut
so
that
clutch
pedal
play
is
in
range
from
II
to
15
mm
0
433
to
0
591
in
at
the
center
of
the
clutch
pedal
pad
and
make
sure
that
play
at
P
point
of
the
withdrawal
lever
is
in
range
from
3
0
to
4
0
mm
0
1181
to
0
1575
in
Secure
the
alignment
with
lock
nut
completely
CL
7
Page 478 of 513
CHASSIS
i
I
I
I
II
I
I
J
u
IlllrP
Zll
I
ff
Pedal
play
11
to
15
I
0
433
to
0
591
I
W
p
da
stfO
l
e
1
P
point
end
play
l
e
A
1
C
3
0
to
A
O
Chassis
grease
20
0
1181
to
0
1575
I
Y
136
5
to
lA6
5
I
5
A
to
5
81
0
Note
Connect
the
control
cable
correctly
so
that
mark
cap
is
faced
upward
as
shown
in
the
following
figure
Make
sure
that
chassis
grease
has
been
I
2
3
Lock
nu
t
Adjusting
nut
Pedal
stopper
applied
to
the
CG
marked
positions
three
places
Apply
grease
if
required
@
300R
t2
8J
Unit
mm
in
Fig
CL
19
Pedal
height
adjustment
3
When
the
clutch
pedal
is
heavy
remove
grease
filler
cap
from
front
portion
of
the
adjust
nut
and
grease
Be
sure
to
use
grease
containing
molybdenum
disulfide
Fig
CL
20
Greasing
to
the
nipple
of
clutch
control
cable
CL
8
Page 479 of 513

CLUTCH
CLUTCH
MASTER
CYLINDER
Hydraulic
clutch
3
V
t
2
3
4
5
6
7
8
9
10
tt
12
13
Snap
ring
Dust
cover
Push
rod
Clutch
piston
Piston
spring
Inlet
valve
spring
Inlet
valve
Spring
retainer
Shim
Inlet
valve
release
pin
Body
Oil
reservoir
Oil
reservoir
cap
6
D
ll
Q
6
i
0
l
Y
r@
cb
Fig
CL
21
Clutch
master
cylinder
Removal
Disconnect
the
push
rod
from
the
clevis
2
Disconnect
the
clutch
line
from
the
master
cylinder
and
drain
fluid
3
Remove
the
securing
bolts
and
remove
the
master
cylinder
assembly
from
the
vehicle
Disassembly
Remove
the
filler
cap
and
drain
fluid
2
Pull
back
the
dust
cover
and
remove
the
snap
ring
The
stopper
push
rod
piston
assembly
primary
cup
and
return
spring
assembly
can
be
removed
Inspection
Thoroughly
clean
all
parts
with
brake
fluid
before
inspection
CL
9
1
Check
the
cylinder
and
piston
for
uneven
wear
or
damage
Replace
if
required
2
When
clearance
between
the
cylinder
and
piston
is
more
than
0
15
mm
0
0059
in
replace
the
cylinder
3
Replace
the
piston
cup
primarily
whenever
the
master
cylinder
is
disassembled
It
must
also
be
replaced
when
wear
or
deforma
tion
due
to
fatigue
or
damage
is
found
4
Check
the
dust
cover
oil
reservoir
filler
cap
and
clutch
line
for
damage
or
deformation
If
abnormal
condition
is
found
replace
with
new
one
Reassembly
Reassemble
the
master
cylinder
assembly
in
reverse
sequence
of
disassembly
noting
the
following
matters
The
piston
cup
should
be
soaked
in
brake
fluid
before
reassembly
Install
the
piston
cup
carefully
so
that
it
is
correctly
faced
Page 480 of 513

CHASSIS
2
Apply
brake
fluid
sufficiently
to
the
cylinder
and
piston
and
assemble
them
Reinstallation
Reinstall
the
master
cylinder
assembly
in
reverse
sequence
of
removal
and
adjust
as
follows
I
Adjust
the
pedal
height
by
changing
the
push
rod
length
2
B
eed
air
out
of
the
hydraulic
system
OPERATING
CYLINDER
Hydraulic
clutch
Removal
Remove
the
return
spring
2
Disconnect
the
clutch
line
from
the
operating
cyl
inder
3
Disconnect
the
push
rod
from
the
withdrawal
lever
4
Release
two
bolts
used
to
mount
the
operating
cylinder
to
the
clutch
housing
Disassembly
1
Remove
the
dust
cover
2
Remove
the
snap
ring
and
all
other
parts
can
be
disassembled
@
Fig
CL
22
Operating
cylinder
disassembled
CL
10
Inspection
Check
all
parts
especially
the
piston
cup
and
replace
if
worn
or
damaged
Reassembly
Reassemble
the
operating
cylinder
in
reverse
sequence
of
disassembly
noting
the
following
matters
Soak
the
piston
cup
in
fluid
before
reassembly
Install
the
piston
cup
carefully
so
that
it
is
faced
correctly
2
Apply
brake
fluid
sufficiently
to
the
cylinder
and
piston
and
assemble
them
Reinstallation
Reinstal
the
operating
cylinder
in
reverse
sequence
of
removal
1
Bleed
air
out
of
the
hydraulic
system
2
Adjust
the
push
rod
so
that
the
withdrawal
lever
end
play
is
0
to
2
0
mm
0
0394
to
0
0787
in
in
accordance
with
the
following
instructions
AD
USTING
WITHDRAWAL
LEVER
Correct
adjustment
of
the
clutch
withdrawal
lever
is
essential
Insufficient
free
travel
between
the
release
bearing
and
the
diaphragm
spring
fingers
causes
the
clutch
to
slip
while
excessive
free
travel
affects
full
disengage
ment
of
the
clutch
The
clearance
between
the
release
bearing
and
the
diaphragm
spring
fingers
can
be
adjusted
at
the
with
drawallever
end
as
follows
Hydraulic
clutch
Loosen
the
lock
nut
tighten
the
adjusting
nut
and
eliminate
clearance
between
the
top
of
the
withdrawal
lever
and
release
bearing
2
Return
the
adjusting
nut
from
that
position
I
4
turns
and
set
the
adjusting
nut
stationarily
with
the
lock
nut