2008 GEELY CK clutch

57Section 1 Clutch ReplacementHoist the engine from the compartment. See "Provison 20, Section 2, Chapter 2".
1. Remove manual transaxle assembly
2. Remove the clutch release fork. See (Figure 132)
3. Detach clutch release fork boot.
4. Detach clutch release bearing
5. Detach clutch release bearing fixed clamp
6. Remove clutch fork pivot pin
7. Align the clutch cover to the mark on the flywheel. Detach clutch cover. See (Figure 133)
8. Remove clutch plate
9. Check and remove clutch plate assembly. See (Figure 134)
10. Check clutch cover. See (Figure 135)
Depth wear: A: 0.6mm
Width wear: B: 5mm
Figure 132 Figure 133
Figure 134 Figure 135

5811. Using the dial gauge, check the flywheel runout. See
(Figure 136).
The maximum runout: 0.3mm
12. Check clutch release bearing
The bearing is permanently lubricated. There is no need to
lubricate or clean.
13. Check clutch plate
14. Install clutch cover. See (Figure 137)
Align the Clutch cover to the mark on the flywheel.
Hint:
(1) Uniformly tighten the bolt in the sequence shown.
Torque: 19 N. m
(2) Shake the clutch plate up and down, left and right to ensure
it is centered, then tighten the bolt.
15. Check and adjust the clutch cover. See (Figure 138)
Check the diaphragm tip flatness with the dial gauge with roller.
Max. roughness: 0.5mm.
16. Install the release fork pivot pin
17. Install clutch release fork boot
18. Install clutch release bearing fixed clamp
19. Install clutch release fork
20. Install clutch release bearing
21. Install manual transaxle assemblyFigure 136
Figure 137
Figure 138

60Section 1 Manual Transaxle Replacement1. Open the engine hood
2. Remove the battery
3. Remove clutch cylinder sub-assembly. See (Figure 140)
4. Detach transmission shift cable assembly. See (Figure 141)
5. Remove the connector and turn on the back-up lamp switch connector.
6. Disconnect vehicle speed sensor
Disconnect vehicle speed sensor connector.
7. Detach the front exhaust pipe
8. Drain transmission oil
9. Detach left & right front wheel hub nut
10. Detach left & right front wheel speed sensor (ABS)
11. Detach front balance rod
12. Detach left & right tie-rod with ball stud pin
13. Detach front balance rod
14. Detach left & right lower swing arm
15. Detach left & right front propeller assembly
16. Hoist the engine from compartment. See "Provision 20, Section 2, Chapter 2"
17. Detach starter assembly
18. Detach engine mounting bracket
19. Detach manual transaxle assembly
20. Install engine mounting bracket
21. Install manual transaxle assembly
22. Connect engine vibration insulating cushions
23. Install starter assembly
24. Install left & right front propeller assembly
25. Connect left & right lower swing arm
26. Connect left & right tie-rod with ball stud pin
27. Connect front balance rod
28. Connect left & right front speed sensor (ABS)
29. Installleft & right front shaft nut
30. Install front exhaust pipe
31. Connect speedometer sensor connector.
32. Connect back-up lamp switch connector.
33. Connect transmission shift cable assembly. See (Figure 141)
34. Install clutch sub-pump assembly. See (Figure 140)Figure 140
Figure 141

91Chapter 3 Clutch Control SystemSection 1 Clutch Control SystemClutch operating system descriptionThis model is equipped with hydraulic and cable clutch control system, respectively used for 1.3L engine
1.5L engine.PROBLEM SYMPTOMS TABLEUse the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.Section 2 Clutch Cable Control MechanismComponentsSympto m Sus pe cte d Are a
1. Clutc h pe da l position (Too low)
2. Control mec ha nism (Stagna tion)
3. Clutc h pe da l fre e stroke (too la rge)
C lut c h doe s not r e le a s e 1. H ydr a ulic pipe line ( A ir in line )
1. Control system (Incorrect assembly & adjustment)
2. Clutc h asse mbly (Fa ulty) Clutch noisyC lut c h s lipsConnect The
Clutch Fork Clutch Cable
Assmbly
Adjusting NutCowl Baffle
Clutch and Brake
Pedal Assembly

92Adjustment1. Check and adjust clutch pedal height
The clutch pedal height should be 180~186 mm. Adjust the pedal by adjusting bolts.
2. Check and adjust clutch pedal stroke and free stroke
(1) The clutch pedal stroke: 134~142mm
(2) The clutch pedal free stroke: 10~30 mm
If the clutch pedal stroke and free stroke are not within specification, adjust it by adjusting the location of
the adjusting nut on the clutch cable. Re-adjust the clutch pedal height if necessary.
3. Check that the clutch pedal operates in flexible and reliable way
Notice:
(1) Make sure the clutch is fully applied and completely released when control the clutch
pedal.
(2) The clutch pedal must have certain free stroke. Otherwise, the full application of the
clutch may be impacted
(3) Tighten the lock nut after adjustmentConnect The
Clutch CableBushingBushingAdjusting BoltBrake Pedal Assembly Sleeve Clutch Pedal Torsion Spring Retainer Pedal MatClutch Pedal AssemblyClutch
Pedal
Bracket
AssemblyAdjusting Nut

93Replacement1. Remove the clutch cable
(1) Loosen the clutch adjusting nut. Separate the clutch cable from the accelerator rocker arm
(2) Remove the 2 set bolts from the clutch cable on the cowl panel
(3) Separate the clutch cable from the clutch pedal
2. Install the clutch cable assembly in the reverse order of the above procedure.
Notice:
(1) The clutch cable assembly on the cowl panel set bolt torque : 20~25N.m
(2) Check and adjust the pedal according to the above-mentioned requirement in
"Adjustment".Adjusting BoltStrokeFree
StrokeMinimum Distance from the Cowl Panel Adjusting Bolt
NutInstall HeightAdjusting Nut

94Section 3 Clutch hydraulic Control DeviceComponents
Clutch Sub-pump
Transmission Assembly
Reservoir
Cowl Baffle
Clutch And Brake Pedal Assembly
Clutch Master Cylinder
Clutch Master
Cylinder
Master Cylinder Bracket
Clamp Clamp
Connect The Pipe Assembly
Hose Union
Reservoir Hose 2Reservoir Hose 1
Clog Bolt
Rubber Washer
Union Nut
Hydraulic Hose
L Shaped Clip Plate L Shaped Clip Plate
Pivot

95Replacement1. Remove the reservoir hose 1 and reservoir hose 2
Notice: Clutch hydraulic control system and hydraulic
brake system share the reservoir. Prevent the brake
fluid from overflowing when removing the reservoir
hose.
2. Disconnect the connection with the pedal
Remove the lock pin, flat washer, pin shaft to separate the clutch hydraulic control master cylinder from
the clutch pedal
3. Remove the connecting pipe
Loose the threaded connector connecting pipe and the clutch master cylinder. Remove the connecting
pipe.
4. Remove the clutch pedal assembly
Remove the nuts, bolts, 2 bushing, sleeve, clutch pedal assembly
5. Remove the hydraulic hose
Loosen the union thread connecting clutch hydraulic hose and pipe. Remove E-shaped clip plate fixing
the both ends of the clutch hydraulic hose