Page 409 of 3051
Components Ð LHD Model with YD Engine ÐNLCL0049
NCL049
1. Clutch pedal bracket
2. Clevis pin
3. Bush
4. Snap pin
5. Pedal stopper bolt
6. Clutch pedal
7. Clutch master cylinder
8. Nipple9. Reservoir cap
10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Air bleeder screw
15. Withdrawal lever16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer
CLUTCH SYSTEM
Components Ð LHD Model with YD Engine Ð
CL-8
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Inspection and AdjustmentNLCL0006CLUTCH PEDAL INSPECTIONNLCL0006S04Pedal StrokeNLCL0006S0401Check clutch pedal stroke by using a 1±meter rule to measure the
total pedal stroke. Place end of rule onto the middle of the clutch
pedal pad. Place a book/clipboard on the driver's seat to set a ref-
erence point, ensure the book/clipboard does not move during
pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the
reference point on the book/clipboard. Measure the distance
between the marks (A and B), this is the actual pedal stroke (S).
Check the specified pedal stroke in the table, adjust actual pedal
stroke if necessary (refer toªCLUTCH PEDAL ADJUSTMENTº).
NOTE:
+Do not use steering wheel as a reference point, angle gives
incorrect reading.
+Ensure there is no interference between the floor carpet and
clutch pedal when fully depressed.
NCL058
SCL702
Pedal Free PlayNLCL0006S0402Check pedal free play, if out of specification refer toªCLUTCH
PEDAL ADJUSTMENTº
+Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
CLUTCH SYSTEM
Inspection and Adjustment
CL-9
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CLUTCH PEDAL ADJUSTMENTNLCL0006S01Pedal StrokeNLCL0006S01011. Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cyl-
inder push rod.
3. Adjust the pedal stopper bolt until it is just in contact with the
pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free
play.
Pedal stroke ªSº.
Refer to ªSDSº, CL-24.
Pedal Free PlayNLCL0006S01021. Adjust pedal free play to the specified value with the master
cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
+Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
Pedal free play ªAº.
Refer to ªSDSº, CL-24.
SCL838
SCL839
AIR BLEEDING PROCEDURENLCL0006S021. Bleed air from clutch operating cylinder according to the fol-
lowing procedure.
+Carefully monitor fluid level at reservoir during bleeding
operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
d. Open the air bleeder with the clutch pedal fully depressed.
e. Close the air bleeder.
f. Release the clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f mentioned above, until clear brake
fluid comes out of air bleeder valve.
Air bleeder valve tightening torque:
: 5.9 - 9.8 N´m (0.6 - 1.0 kg-m, 52 - 86 in-lb)
CLUTCH SYSTEM
Inspection and Adjustment (Cont'd)
CL-10
Page 412 of 3051
ComponentsNLCL0007
NCL052
NCL053
CLUTCH MASTER CYLINDER
Components
CL-11
Page 413 of 3051

RemovalNLCL00081. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin between clutch pedal and push rod, and
remove clevis pin.
4. Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.
InstallationNLCL00091. Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.
2. Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.
: 13 - 16 N´m (1.3 - 1.6 kg-m, 10 - 12 ft-lb)
3. Tighten clutch tube flare nut using a flare nut torque wrench.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. After installing clevis pin, install snap pin to connect clutch
pedal to push rod.
5. After finishing the operation, bleed air from clutch piping con-
nector and operating cylinder. (Refer to ªAir Bleeding
Procedureº, CL-10.)
SCL725
DisassemblyNLCL00101. Loosen push rod lock nut A to remove clevis and lock nut A.
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to
prevent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
InspectionNLCL0011Check the following items, and replace if necessary.
+Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
+Piston with piston cup, for wear or damage
+Return spring, for wear or damage
+Dust cover, for cracks, deformation or damage
+Reservoir, for deformation or damage
CLUTCH MASTER CYLINDER
Removal
CL-12
Page 414 of 3051
AssemblyNLCL00121. Apply rubber lubricant to the sliding part of piston assembly,
and insert piston assembly.
2. After installing stopper to push rod, install stopper ring while
keeping piston assembly depressed by hand, so that piston
assembly will not pop out.
CAUTION:
Stopper ring cannot be reused. Always use a new stopper ring
for assembly.
3. Install dust cover.
4. Install clevis to push rod, and tighten lock nut A to the speci-
fied torque.
:8-10N´m(0.8 - 1.1 kg-m, 70 - 95 in-lb)
5. Install spring pin using a pin punch.
CLUTCH MASTER CYLINDER
Assembly
CL-13
Page 415 of 3051
ComponentsNLCL0019
YCL001
RemovalNLCL00201. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove union bolt and clutch hose from operating cylinder.
3. Remove operating cylinder mounting bolts, and remove cylin-
der from vehicle.
DisassemblyNLCL0021Remove dust cover, and remove piston assembly from cylinder
body.
InspectionNLCL0022Inspect for following, and replace parts if necessary.
+Damage, foreign material, wear, rust, and pinholes on the cyl-
inder inner surface, piston, and sliding part of piston cup
+Weak spring
+Crack and deformation of dust cover
OPERATING CYLINDER
Components
CL-14
Page 416 of 3051
AssemblyNLCL00231. Apply recommended rubber grease to piston cup and piston,
and insert piston assembly.
2. Install dust cover.
InstallationNLCL0024Install the components in the reverse order of removal. Adhere to
the operations described below.
CAUTION:
Install the hose without twisting it.
+The copper washer of the union bolt should not be reused.
Always use a new copper washer for installation.
+After finishing the operation, bleed air from the clutch
piping connector and operating cylinder. Refer to ªAir
Bleeding Procedureº, CL-10.
OPERATING CYLINDER
Assembly
CL-15