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CLUTCH TROUBLESHOOTING
TROUBLESHOOTING
CL02N07
D07509
8 0.5 mm
(0.31 0.020 in.) Q08667
COMPONENTS
Luggage Compartment
Trim Box Cover
Clutch Master Cylinder Clip
x 18
Pin
Clutch Line
18 (185, 13)*
20 (204, 15)
12 (120, 9)
Clip
12 (120, 9)
Cap
Float
Reservoir
Piston
z Grommet
Spring Boot
Washer
Master Cylinder Body
REMOVAL
1. REMOVE LUGGAGE COMPARTMENT TRIM BOX
COVER
D07519
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Using a pin punch and a hammer, tap out the slotted
spring pin.
(b) Remove the reservoir.
(c) Remove the grommet from the reservoir.
(d) Remove the cap and float from the reservoir
2. REMOVE CLEVIS
D07514
Loosen the lock nut, and remove the clevis and lock nut.
Push
D07515
REASSEMBLY
1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSERT PISTON WITH SPRING INTO CYLINDER
D07516
(c) Using a pin punch and a hammer, tap in the slotted spring
Protrusion pin.
1.5 2.5 mm
(0.059 0.098 in.)
D07517
INSTALLATION
1. INSTALL CLUTCH MASTER CYLINDER
(a) Install the master cylinder with the 2 nuts.
Torque: 12 Nm (120 kgfcm, 9 ftlbf)
(b) Connect the push rod to the clutch pedal with the pin and
pin clip.
D07519
COMPONENTS
x6
Clip
Front Engine Under Cover
D08850
12 (120, 9)
Bleeder Plug
8.3 (85, 73 in.lbf)
Clutch Line
14 (143, 10)*
15 (155, 11)
Spring
Piston
Push Rod
Boot
Nm (kgfcm, ftlbf) : Specified torque
*For use with SST
Lithium soap base glycol grease D07523
REMOVAL
1. REMOVE FRONT ENGINE UNDER COVER
D09065
D09067
DISASSEMBLY
1. REMOVE BOOT AND PUSH ROD
(a) Pull out the boot with the push rod.
(b) Remove the boot from the push rod.
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON AND SPRING INTO CYLINDER
3. INSTALL BOOT AND PUSH ROD
(a) Install the push rod to the boot.
(b) Install the boot with the push rod to the cylinder.
Z07291
INSTALLATION
1. INSTALL RELEASE CYLINDER
Install the release cylinder with the 2 bolts.
Torque: 12 Nm (120 kgfcm, 9 ftlbf)
D09067
CLUTCH UNIT
CL02Z05
COMPONENTS
See page (EM59)
z 1 st 49 (500, 36)
2 nd Turn 90
19 (195, 14)
Release Bearing
x6
Clip
Release Fork
Flywheel
Clutch Disc
Clutch Cover
REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE
(See page MX4)
2. REMOVE CLUTCH COVER AND DISC
(a) Align the matchmarks on the clutch cover with the one on
the flywheel.
(b) Loosen each set bolt one turn at a time until spring tension
Matchmarks is released.
D00202
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
Q01056
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using vernier calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
Q01057
Q06033
D00203
Z10408
Q01060
SST INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
Flywheel Side (a) Insert SST in the clutch disc, then insert them in the fly-
wheel.
SST 0930100210
HINT:
Take care not to insert clutch disc in the wrong direction.
D07710