CLUTCH

SECTIONCL

- col{rEl{Ts
PFECAOTIONS AND PFEPABA'TION ct2
C I U T C HS Y S T F M
INSPECTION ANOADJIJSTMENT
HYDFAULIC CLUTCHCOI{TFOL
C L U T CFHE L E A SVEE C h A N t S.i.'. . . . . . . . . . . . c!- I
cLUTCHDtSCAN0CLUTCH COVE8......................,............... cL-11
SEFVICE DAIAANDSOECIFICATIONS (S D S )
PRECAMONSANDPREPARATION

Prec€utions
. F..s|Mdcd tuld h clulchiuid DoT 4".
. Do not d@ d6in€d cluich nuH.
. B€eBtul norro .pL.h durch fuld d palntedatE4
. whs movlng and In.talrlngcrrrch plphq, u* Tdr,
. To d@n or sah .ll p.rta ol n..Lr qll.dd, op.hllng
\ cylind€r.nd durch d.mp€f, ue .L.n cldch n!id.
. Nffi us miEr.l0116 6@h a qa&llre d k€tE€B. hfill
ruin rlE rub6€r p.ft ol rhe hydautic sy.tm.

Rm@ 6ll d6r fiom clurch d$ lith a dust 6[.ctor 6tt6r

clening wilfi male cloth,

Preparalion
SPECIALSERVICETOOLS

h3p*r is d aph60mspdnsorc urh 6ver

6
Adjudis M6vam€$ or diaphnqmspdnso'

cL-2
 CLUTCHSYSIEM

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@ crlbh d.ho.r (SF2oDE
.is i.

CL€
INSPEC]IONANDAD.JUSTMENT

AdiustingClutchPedal
1. Adjuslp€dalhoighlwilh peda sloppei
R.H,D.222- 232mn (&74- f.i3 h)
LH,D.242- 252nn {9,53- 9.S2int

2. Ad.u6rp€dallc6 playwiihm€sr€r pusr^rod.Th€n

cyl,nde.
_
P.d.llts pr.y "a :
iI) - 3.0nm (0.@9- 0,1la hl
tud ns pby nEE rheiolldlng bdt nE6uEd d pQrdon

. Flaydu. to cbvL pln .nd cLvl. pln hot. in durch pedar,

3. Mak6suB lhat cl€visDin€n be rclat6dsmoothlv.
ll rol. r6rdju6lp€darl'eeplayulh mad* cvlnd€rpush

cL4
INSPECTION
ANDADJUSTMEiIT

BleedlngProcedu|e
L Blsd an trom clulch opeBling cylindera@rding ro th€
cr.lully noilo. nuld Lsl n nard .yiftr* dudnsbteedt.g
Too !D r6$ruoirwilh €@hme.ded bEke lllld.
Conn@r a lrmspa€nt vinyl tube to air bt6.d.f vatve ol
clutchop€EtnAcylind€r.
Fullyd6pEs. clulchp6dals6v€Elrimes.
Wilh clulch pedaldepess€d, op6n bl€€dervalve to rcte6g
e. Close bl€€d$ valve.
L Rapeatsteps c though e abov€ unritb6k. nuid ttowsnom
air bleedervalvowirhoutan blbbles.
2. Bleed air lrcm clutch damp.r ac@ding lo lh€ abov. pro-
6du€ (SB2oDEenqlnemoderonty).
3. R€p6al th€ abov. bleeding prcc.durc. 1 and 2 *veEl
 HYDRAUUC
CLUTCHCOMINOL

ClutchMasterCylindet

-1
)

Pl!n
E@:H'
,[

DISASSEi'BLY
ANDASSEMBLY
. lushpistonintocylinddbodywitl$r4driverwh6nrBmov,
ing and insiallinq
valv. siopper.

. Aliqngr@ve ol pislonass6frblyand valv6 stopp€.when

in.rallinqvd@ stopper.
. Checkdn€dionol pistoncups.
0!0r0mutul!
tsTl=tllr

I
cL5
 HYDRAULIC
CLUTCHCOI.ITROL

ClutchOFeratingCylinder

NSPEqflON
. Ch@k rubbingsurace ol cylinderror woar, tusl of d6maga.
F€pla@ il neessry.
. Chek pislon wilh pislon cup lor w€ar or damage.R€da@
. Ch4k dust @ver lor cEcks, delomslion of damage.
F€da@ il n66ssary.
. Chsk pislonspnngforwearor damag€.Beplaceit ne@s-

cL-7
 HYDRAUUCCLUTCH@NTBOL

Cluicfi Damper(SF|2oDE
enginemod6l5only)

9$oi.x.u,\.,/
E@6ms' 4turbpid{sFbt

bf

INSPECTION
. ch6ck cylnderandpislonrubblngsufa@ lor unev€nw€ar,
rud or dama06.Beplaceif necGsary.
. Checkdampd rubberand prsloncuplor cr&k., d€roma-
tion or damage.F6plac6il n€€ssary.

cL{
CLUTCHRELEASEMECHANISM

M'l
EO Ad iFlmn$o,E@ dd

FEMOVALAND INSTALLAIION
. Insiallrelainerspnng.fd
holde.sping.

. Bemov€cle.* bearng.

r Instalcle* b€anngwithsulabb dnft.

CL€
 CLUTCHRELEASEI'ECHANISM

INSPECNON
. Check€le6€ be,ing to s6 lhat ll olls t€ely and ls l@
fom nols, cEcks, phdlg or woaf,Fed@ n ne*ary.
. Ch6ckbl€ee dsve andwflhd€wd 16@rrubbingsudac€
for ser, tu€tor damg.. Feda@ il n€@6ery,

LUBMCAIION
. Apply@mm€ndedgrca$ to onrqcl .url&. sndrubbing
T@ mDh lub.l@nt nlght 6E .rurdt de bcrrE d.ng€,

aEo ^dYrhqdsdr.g ddr4

cl--l0
CLUTCHDISCANDCLUTCHCOVEF

clutch Disc
INSPECTION
. ch6ck clutchdi6clor wearol tacing.
Wdr llnt ot tadng urfae b ln6i h6d:
0,3nn (0012In)

. Chek.lulch dl$ Iorsplin€backlash

andraclnorunout.
Mdlnum .pliE b*ldah (.t ourereds. ot dk I
2m TBr-20OLDB:OOmm(o.Gtr|n)
225LTI} 0.9hm (0.@5In)
1O m lo,Grgln)
d.ra.e ot runolr ch.d( polnt(lbn hubqter):
200lBlrloo u)A: 95 fim (t74In)
225LID: 1075nn (423 In)
. Checkclurchdi& tor bums,ds@lo€tionor oitor g6a.e
l6akaq6.R6pla@ll ne@ssary.
INSTALLATION
g'easeb conr.d sud.c€ol spnnq
. Apply@ommended
t@ mudr tubndn| hishr &r4e crutchdle f.clngl

cL.l1
 CLUTCHDISCANDCLUTCHCOVER

ClutchCoverand Flywheel
INSPECNON ANO AA'USTMEM
. Sel Toolsandcheckheiqhtandun€v..nessol diaphraqm
Dlgphdgn .pdng h.iglt "4":
cat6DE: 3a.4 - /O,4 mm (1.512_ 15SOIn)
SF2ODe 325 - 395 mm (1176 - 1 555 in)
lD2cll: 31.0- 330 nn (1220 - 1l99 in)
r ch6ci lhrJsl nngslor w€sr or danage by sh.king.ov€r
as$mb v and I'slenholorchan€rias-oi*, o' ligtllyh6m-
m6nnqon rlvets lor a sliqhl cbcking nois6. Repla@ clulch
@er assemblvil n€cessdry.
. ch€ck pressu€ plala and alutch disc co.iacl suiace to.
slighl buns or di@loalion Fepan p€ssurB plsle wilh
. Check or€ssuE plat6 and clulch disc coniacl surfa€ lor
detomalion or damags. Bepla@il nec€ssary.

. ot diaph€gmspdngwilhTool.
adjlsl un€v€nn€es
0.7mm(0.@8in)

Eg""-s9
ni\q{P?

FLYWHEEL
INSPECTION
. Check@ntacl sudacBol nyrvh€61 lor slight buns or discol
oEtion.F€panflyrvh€Bl wilh€m.rypaper.
. Check tlywh€.| runoul.
Fooul (tolrl lrderor Edlng):
R4Grlo EM *cllon. 0n.eclid - CYUNDER
BLOCn

cl-l2
I CLUTCH
DISCANDCLUICHCOVEH
CluichCov€ra.d Fllrwh*l (Confd)
tNsTLtaTtoll
. l6et T@l Intoclurchdlschlb sh€. In6talllngclutch@sr
. nohton bolE in nuh6nerod6l
. B€carctulnol io.llow !r!..3io coibmh.bdubt Hng.

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 (S.D.S.}
SERVICEOATAANDSPECIFICA]IONS

GeneralSDecificatlons
CLUTCHCONIROL SYSTEIIII cLuTcHosc

CLUrcH MASTERCYUNOEF

CLUTCHOPEFATING
CYUNDEF
CLUTCHCOVEF

CLUTCHOAMPER

InspectionandAdiustment
CLUICH PEDAL CLUTC COVEF

CLUTCHDISC

cL-l4