Page 561 of 3342
B2M0055
3) Install rear exhaust pipe to center exhaust pipe.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
8
2-9SERVICE PROCEDURE
2. Rear Exhaust Pipe
Page 562 of 3342
B2M0061
3. Muffler
A: REMOVAL AND INSTALLATION
1) Separate muffler from rear exhaust pipe.
B2M0062
2) Remove left and right rubber cushions.
CAUTION:
Be careful not to pull down muffler.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushions in advance.
SUBARU CRC (Part No. 004301003)
B2M0063
3) Remove front rubber cushion, and detach muffler
assembly.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
B2M0061
4) Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
48±5 N⋅m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
9
2-9SERVICE PROCEDURE
3. Muffler
Page 563 of 3342
1. Clutch System
A: SPECIFICATIONS
2200 cc 2500 cc
Clutch cover Diaphragm set load kg (lb) 450 (992) 550 (1,213)
Clutch discFacing material Woven
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
Spline O.D. mm (in)
(No. of teeth)25.2 (0.992)
(24)
Clutch release lever ratio 3.0 1.6
Release bearing Grease-packed self-aligning
B: SERVICE DATA
2200 cc 2500 cc
Clutch pedal Full stroke mm (in) 140 — 150 (5.51 — 5.91)
Release leverStroke mm (in) 24 — 26 (0.94 — 1.02)
Play at release lever center mm (in) 3 — 4 (0.12 — 0.16)
Clutch discDepth of rivet head
mm (in)Standard 1.3 — 1.9 (0.051 — 0.075)
Limit of sinking 0.3 (0.012)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)
2
2-10SPECIFICATIONS AND SERVICE DATA
1. Clutch System
Page 564 of 3342
1. Clutch System
1. MECHANICAL APPLICATION TYPE
B2M0632A
1Clutch cable bracket
2Clutch release lever sealing
3Retainer spring
4Pivot
5Clutch release lever
6Clip
7Clutch release bearing
8Clutch cover
9Clutch disc
10Return spring (Models without hill holder only)
11Clutch return spring bracket
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5 (1.6±0.15, 11.6±1.1)
3
2-10COMPONENT PARTS
1. Clutch System
Page 565 of 3342
2. HYDRAULIC APPLICATION TYPE
B2M1009B
1Snap pin
2Clevis pin
3Master cylinder ASSY
4Bracket
5Clutch hose B
6Clutch damper
7Damper bracket
8Clutch hose A
9Operating cylinder
10Clutch release lever sealing
11Retainer spring
12Pivot
13Release lever
14Clip
15Release bearing
16Clutch cover
17Clutch disc
18Flywheel
19Spacer
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5
(1.6±0.15, 11.6±1.1)
T2: 18±3 (1.8±0.3, 13.0±2.2)
T3: 25±7 (2.5±0.7, 18.1±5.1)
T4: 37±3 (3.8±0.3, 27.5±2.2)
4
2-10COMPONENT PARTS
1. Clutch System
Page 566 of 3342
2. Master Cylinder and Reservoir Tank
G2M0976
1Reservoir cap
2Reservoir tank
3Reservoir band
4Seat
5Master cylinder
6Piston
7Push rod
8Piston stop ring
5
2-10COMPONENT PARTS
2. Master Cylinder and Reservoir Tank
Page 567 of 3342

1. General
A: PRECAUTION
When servicing clutch system, pay attention to the follow-
ing items.
1. MECHANICAL APPLICATION TYPE
1) Check the routing of clutch cable for smoothness.
2) Excessive tightness or looseness of clutch cable have
a bad influence upon the cable durability.
3) Apply grease sufficiently to the connecting portion of
clutch pedal.
4) Apply grease sufficiently to the release lever portion.
5) Position clutch cable through the center of toe board
hole and route it smoothly. Adjustment is done by moving
the outer cable.
6) Make sure not to let the clutch chatter when starting
forward or rearward. If clutch chattering occurs, readjust so
that the bend of clutch outer cable becomes flatter.
B2M1177A
2. HYDRAULIC APPLICATION TYPE
1) Check fluid level using a scale on outside of reservoir
tank. If 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 pre-
vent 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.
2) Make sure that clutch fluid does not leak from master
cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever pinion.
4) Check for proper clutch disengagement and clutch
pedal return ability.
G2M0234
2. On-Car Service
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring from lever (Models
without hill holder only).
2) Adjust spherical nut so that the play is within the speci-
fied value at the lever end (center of spherical nut).
CAUTION:
Take care not to twist the cable during adjustment
Play: 3 — 4 mm (0.12 — 0.16 in)
Full stroke: 24 — 26 mm (0.94 — 1.02 in)
6
2-10SERVICE PROCEDURE
1. General - 2. On-Car Service
Page 568 of 3342

1. General
A: PRECAUTION
When servicing clutch system, pay attention to the follow-
ing items.
1. MECHANICAL APPLICATION TYPE
1) Check the routing of clutch cable for smoothness.
2) Excessive tightness or looseness of clutch cable have
a bad influence upon the cable durability.
3) Apply grease sufficiently to the connecting portion of
clutch pedal.
4) Apply grease sufficiently to the release lever portion.
5) Position clutch cable through the center of toe board
hole and route it smoothly. Adjustment is done by moving
the outer cable.
6) Make sure not to let the clutch chatter when starting
forward or rearward. If clutch chattering occurs, readjust so
that the bend of clutch outer cable becomes flatter.
B2M1177A
2. HYDRAULIC APPLICATION TYPE
1) Check fluid level using a scale on outside of reservoir
tank. If 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 pre-
vent 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.
2) Make sure that clutch fluid does not leak from master
cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever pinion.
4) Check for proper clutch disengagement and clutch
pedal return ability.
G2M0234
2. On-Car Service
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring from lever (Models
without hill holder only).
2) Adjust spherical nut so that the play is within the speci-
fied value at the lever end (center of spherical nut).
CAUTION:
Take care not to twist the cable during adjustment
Play: 3 — 4 mm (0.12 — 0.16 in)
Full stroke: 24 — 26 mm (0.94 — 1.02 in)
6
2-10SERVICE PROCEDURE
1. General - 2. On-Car Service