Pumping the clutch hydraulic drive Note: after any work related to the ingress of air into the clutch hydraulic system, bleed it. Caution: Do not allow brake fluid to come into contact with painted surfaces. If brake fluid comes into contact with a...
Checking and adjusting the clutch pedal travel 1. Check the height of the clutch pedal from the floor. Pedal height from butt: Models up to 96 g - 152-162 mm Models with 96 g - 149-159 mm 2. Adjust the pedal height if necessary. To do this, loosen the locknut and...
Removing the clutch release master cylinder 1. Using a syringe, remove liquid from the cylinder 2. Using the special tool, disconnect the clutch hydraulic tube and drain the fluid into a container. 3. Remove cotter pin and fork axle. 4. Turn away two fixing nuts...
Clutch Master Cylinder Check Note: Blow out the disassembled parts of the clutch cylinder with compressed air. 1. Check the cylinder mirror for rust and scoring. If necessary, replace the cylinder. 2. Check piston and cups for scratches, nicks,...
Clutch master cylinder assembly 1. Lubricate the surfaces indicated by the arrows in the figure. 2. Insert the piston into the cylinder. 3. (Models up to 96 onwards) Install the stem assembly with a new piston stopper. (Models from 96 onwards) Install...
Clutch master cylinder installation 1. Install the clutch master cylinder and tighten the mounting nuts. Tightening torques for fastening nuts: Models up to MY 96: 7.8 Nm Models from 96 onwards: 12 Nm 2. Using a slotted tool, connect the clutch hydraulic...
Removing the clutch release slave cylinder 1. (Models up to 96 g.e. with 3S-GE engine) Remove the protective cover. A) Loosen the two screws and remove the protective cover. b) Loosen the bolt securing the tube to the bracket. (Models from 96 g.e.) Turn away a...
Disassembly of the working cylinder of the clutch release actuator (Models up to 96 onwards) Clutch release slave cylinder: 1 - bleed valve, 2 - cylinder body, 3 - spring, 4 - piston, 5 - rod, 6 - boot, 7 - protective cover (Models from 96 onwards) Clutch release slave cylinder: 1 -...
Checking the clutch release slave cylinder Note: blow the disassembled parts of the clutch slave cylinder with compressed air. 1. Check the cylinder mirror for rust and scoring. If necessary, replace the cylinder. 2. Check the piston and cups for scratches,...
Clutch Release Slave Cylinder Assembly 1. Apply grease to the piston. 2. Insert the piston with the spring into the cylinder. 3. Put on the boot and insert the rod and the cylinder. 4. Install the bleed screw.
Installing the clutch release slave cylinder 1. Install the slave cylinder. A) (Models up to 96 onwards with 3S-GE engine) Install the slave cylinder with the tube bracket and tighten the two bolts. Tightening torque 72 Nm. b) (Other models) Install the slave...
Removing the clutch Clutch: 1 - clutch disc, 2 - release bearing, 3 - case, 4 - clutch release fork, 5 - clutch cover, 6 - flywheel, 7 - clutch disc 1. Remove the gearbox. (see related section). 2. Remove the clutch cover and disc: A) Put...
Checking Clutch Parts 1. Check the clutch disc for wear and damage. Using a caliper, measure the depth of the rivet heads from the lining surface. Minimum rivet depth 0.3 mm. If the depth is less than acceptable, repair or replace the clutch...
Clutch installation 1. Install the clutch disc and clutch cover to the flywheel. A) Using a centering mandrel, install the disc and clutch cover. b) Align the alignment marks on the clutch cover and flywheel. V) Temporarily tighten bolts...