CL-1

Clutch
Pages
Troubleshooting.................................................................................................................................................CL-2
Check and adjust clutch pedal...........................................................................................................................CL-3
Deflation of clutch.............................................................................................................................................CL-3
Clutch master cylinder.......................................................................................................................................CL-4
Clutch slave cylinder..........................................................................................................................CL-5
Clutch assembly.................................................................................................................................................CL-6

ININ CL

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 CL-2 Clutch — troubleshooting

Troubleshooting

Problem Possible Cause Remedy

Adjust free stroke of
Free stroke of clutch pedal too long
clutch pedal
Air in clutch pipeline
Exhaust air in clutch
Clutch slave cylinder faulty
system
Difficult to change Clutch master cylinder faulty
Displace slave cylinder
gear or cannot change Installation position of clutch disc faulty
Displace master cylinder
gear Friction lining is stuck to oil or broken
Check clutch disc
Spline of input shaft or clutch disc is contaminated or adhered
Repair as necessary
to something
Displace clutch pressure
Clutch pressure disc faulty
disc
Displace guide bearing
Guide bearing of clutch worn Adjust free stroke of
Transmission not
Free stroke of clutch pedal short clutch pedal
meshing
Friction lining of clutch disc is adhered to oil or worn Check clutch disc
Clutch sliding
Clutch pressure disc faulty Displace clutch pressure
Release fork seized disc
Check release fork
Check clutch disc
Friction lining of clutch disc is adhered to oil or worn
Clutch seized/ Displace clutch pressure
Clutch pressure disc faulty
vibrating disc
Engine bracket loose
Repair as necessary
Air in clutch pipeline Exhaust air in clutch
Clutch slave cylinder faulty system
Clutch pedal spongy
Clutch master cylinder faulty Displace slave cylinder
Displace master cylinder
Displace clutch pressure
Components and parts loose in clutch pressure disc
disc
Release bearing worn or contaminated
Clutch loud noise Displace release bearing
Guide bearing worn
Displace guide bearing
Release fork seized
Repair as necessary

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 Clutch — check and adjust clutch pedal; deflation of clutch CL-3

Adjusting point of push rod stroke Check and adjust clutch pedal
1． Check pedal height and position of push rod, right or not.
Pedal height is counting from front boarding.

Admiral （165±5）mm
Adjusting point of
If wrong, adjust pedal height.
pedal height 2. If necessary, adjust pedal height.
（1）Loosen locknut, swivel the bolt until the height is right. Install
Pedal height the locknut.
（2）Loosen locknut, swivel the push rod until the position is right.
Install the locknut.

3. Check whether free stroke of pedal is right or not.

Press the pedal gently until you could feel the resistance force
against the clutch.
Free stroke of pedal: 16-28 mm
4. If necessary, adjust free stroke of pedal.
（1）Loosen locknut, swivel push rod until the stroke is right.
（2）Install the locknut.
（3）After adjusting free stroke of pedal, check pedal height.
Free stroke of pedal

Deflation of clutch
Remarks: If operating the clutch system or air in the clutch, you
should exhaust the air.
Note：Do not leave brake fluid on the painting surface. If yes, wash
it away immediately.
1．Inject the brake fluid into the oil cup of the clutch master
cylinder.
Check the oil cup of the master cylinder regularly. If necessary,
inject the brake fluid.

2．Connect ethylene resin tube to deflation valve.

Insert the other end of the tube into the container which
contains half of brake fluid.
3．Deflation of clutch system
（1）Make upward and downward reciprocating motion of the
clutch pedal several times slowly.
（2）When putting pressure on the pedal, loosen the deflation valve
until the brake fluid flows out, and then install the deflation
valve.
（3）Make the abovementioned operations repeatedly until the
bubble in the brake fluid disappears.

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 CL-4 Clutch — clutch master cylinder

Clutch master cylinder

Components

Pin spindle
Toggle fork
Elastic clamping Locknut
band
Cotter pin
Connecting hose
Clutch master
Elastic clamping cylinder
band

Pushrod

Fluid supply
connector

Clutch control
oil tube

单位N﹒m
Unit: N·m

Removal of clutch master cylinder

1．Remove cotter pin and pushrod pin.

2．Take apart clutch control oil tube with a spanner.

3．Remove elastic clamping band.

4．Remove clutch master cylinder.

（1）Remove fixing nut.
（2）Pull the clutch master cylinder.

Installation of clutch master cylinder

1．Install the fixing nut and swivel.

2．Link up the clutch control oil tube.

3．Link up the pushrod, and install the pin and cotter pin.

4．Connect the connecting hose to the fuel outlet connector of the

clutch master cylinder with elastic clamping band.

5．Exhaust air in the clutch system, and adjust the height of the
clutch pedal.

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 Clutch—clutch slave cylinder CL-5

Clutch slave cylinder

Components

Clutch slave
cylinder Bleed ing plug

18±2N·m
19±1N·m

Piston Pushrod
Spring
Dust cover

Fixing nut

Seal
gasket

Sealing bolt

Locknut Adjusting nut

◆ 用过后不能再使用的零件

Removal of slave cylinder

1．Take apart the clutch pipeline.

2．Loosen the two bolts, remove the clutch slave cylinder.

Installation of slave cylinder

1．Install slave cylinder with two bolts.

2．Link up clutch pipeline.

3．Exhaust air in clutch system.

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 CL-6 Clutch—clutch assembly

Clutch assembly

Components

Flywheel

Clutch disc Clutch pressure disc 30 N·m

Locating clip of
release bearing
Release fork

Dust cover

Release bearing

Support pin of release fork

Removal of clutch components

1．Remove transmission
Remarks: Do not make gear oil dried.

2．Remove clutch pressure disc and clutch disc

（1）Mark the clutch pressure disc and flywheel with an alignment
mark. (Alignment mark: in order to keep dynamic balance,
you need to install them by the mark.)
（2）Loosen the bolt slowly until the spring tension is fully
released.
（3）Loosen the fixing bolt, pull the clutch pressure disc and clutch
disc.

3．Take apart the bearing and release fork from transmission

4JB1、491 Engine：
（1）Remove the clip, pull the bearing.
（2）Remove the release fork and dust cover.

4YDA1K、SD4W55A Engine：
（1）Remove the dust cover.
（2）Remove the release fork, pull the bearing.

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 Clutch—clutch assembly CL-7

Checking of parts of clutch

1．Check the clutch disc, if worn or damaged
Measure the depth of rivet head with a vernier caliper.
The minimum depth of the rivet head: 0.3mm
It’s necessary to displace the clutch disc if the depth of rivet
head exceeds the limit value.

2．Check the radial runout of the clutch

百分表
Dial indicator Runout mandrel Check the radial runout of the clutch disc with a dial indicator.
摆差芯轴 Max. Radial Runout: 0.8mm
It’s necessary to displace the clutch disc if the radial runout
exceeds the limit value.

摆差仪
Runout instrument

3．Measure the radial runout of the flywheel

Check the radial runout of the flywheel with a dial indicator.
Max. Radial Runout: 0.2mm
It’s necessary to displace the flywheel if the radial runout
exceeds the limit value.

4．Check the guide bearing

Apply a force in the direction of axial line, turn the bearing by
hand.
It’s necessary to displace the guide bearing if it cannot be turned
or too much resistance existed.
Remarks：This bearing is permanently lubricated. Thus it is no
need to be cleaned and lubricated.

5．If necessary, displace the guide bearing.

（1）Remove the guide bearing.

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 CL-8 Clutch — clutch assembly

（2）Install the guide bearing.

Remarks： After fitting the guide bearing into the flywheel
hub, make sure rotation of the bearing in good condition.

2．Check whether the diaphragm spring is worn or not.

Check the wearing depth and width of the diaphragm spring
with a vernier caliper.
Limit value：
Max. depth：0.6mm
Max. width：5mm
It’s necessary to displace the diaphragm spring if the wearing
depth and width of the diaphragm spring exceeds the limit
value.

3．Check release bearing

Apply a force in the direction of axial line, turn the bearing by
hand.
It’s necessary to displace the release bearing if it cannot be
turned or too much resistance existed.
Remarks：This bearing is permanently lubricated. Thus it is no
need to be cleaned and lubricated.

Installation of clutch assembly

1．Locate the friction disc and flywheel through guide bearing of
crankshaft by using special tools.（locating shaft or locating pin）.
At the
side of
飞轮侧
flywheel

2．Installation of clutch pressure disc

（1）The mark is used to align the clutch pressure disc and flywheel,
and to make sure of keeping dynamic balance of crankshaft,
Alignment
mark
flywheel and pressure disc.(Alignment mark：make sure of
对准标记 keeping dynamic balance of crankshaft, flywheel and pressure
disc).
（2）Install the bolts with a balanced force. Apply a force around
the clutch pressure disc repeatedly until they are closely
jointed. Then tighten the bolts.
Moment of tightening：25-30 N·m
Remarks：
Order of tightening the bolts: each bolt should be tightened
one by one according to a diagonal line to ensure that each
bolt is under uniform stress.

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 Clutch — clutch assembly CL-9

4．Smear No.2 lithium- based lubricant

Smear the lithium- based lubricant as follows:
· contact point of release fork and bearing cover
· contact point of release fork and pushrod
· fulcrum of release fork
· spline of clutch disc

5．Fit the dust cover, release fork, release bearing seat and bearing
into transmission

6．Install the transmission

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