C TRANSMISSION/TRANSAXLE

B
SECTION
CLUTCH CL

E
CONTENTS
QG18DE Inspection and Adjustment ..................................... 17 F
CLUTCH DISC .................................................... 17
PRECAUTIONS .......................................................... 3 CLUTCH COVER AND FLYWHEEL ................... 18
Precautions .............................................................. 3 FLYWHEEL INSPECTION .................................. 18 G
PREPARATION ........................................................... 4 Installation .............................................................. 18
Special Service Tools ............................................... 4 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 19
Commercial Service Tools ........................................ 4 Clutch Control System ............................................ 19
NOISE, VIBRATION, AND HARSHNESS (NVH) H
Clutch Master Cylinder ........................................... 19
TROUBLESHOOTING ................................................ 5 Clutch Operating Cylinder ...................................... 19
NVH Troubleshooting Chart ..................................... 5 Clutch Disc ............................................................. 19
CLUTCH SYSTEM ...................................................... 6 Clutch Cover ........................................................... 19 I
Components ............................................................. 6 Clutch Pedal ........................................................... 19
Inspection and Adjustment ....................................... 7
CLUTCH PEDAL INSPECTION AND ADJUST- J
MENT .................................................................... 7
QR25DE
BLEEDING PROCEDURE .................................... 7 PRECAUTIONS ........................................................ 20
CLUTCH MASTER CYLINDER .................................. 9 Precautions ............................................................. 20
Components ............................................................. 9 K
PREPARATION ......................................................... 21
Removal ................................................................... 9 Special Service Tools ............................................. 21
Disassembly ............................................................. 9 Commercial Service Tools ...................................... 21
Inspection ............................................................... 10 NOISE, VIBRATION, AND HARSHNESS (NVH) L
Assembly ................................................................ 10 TROUBLESHOOTING .............................................. 22
Installation .............................................................. 10 NVH Troubleshooting Chart ................................... 22
OPERATING CYLINDER ...........................................11 CLUTCH SYSTEM .................................................... 23 M
Components ............................................................11 Components ........................................................... 23
Removal ..................................................................11 Inspection and Adjustment ..................................... 24
Disassembly ............................................................11 CLUTCH PEDAL INSPECTION AND ADJUST-
Inspection ................................................................11 MENT .................................................................. 24
Assembly ................................................................ 12 BLEEDING PROCEDURE .................................. 24
Installation .............................................................. 12 CLUTCH MASTER CYLINDER ................................ 26
PIPING ...................................................................... 13 Components ........................................................... 26
Removal ................................................................. 13 Removal ................................................................. 26
Installation .............................................................. 13 Disassembly ........................................................... 26
CLUTCH RELEASE MECHANISM .......................... 14 Inspection ............................................................... 26
Components ........................................................... 14 Assembly ................................................................ 27
Removal ................................................................. 14 Installation .............................................................. 27
Inspection ............................................................... 14 OPERATING CYLINDER .......................................... 28
Installation .............................................................. 14 Components ........................................................... 28
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 17 Removal ................................................................. 28
Components ........................................................... 17 Disassembly ........................................................... 28
Removal ................................................................. 17

CL-1
 Inspection ............................................................... 28 Removal ..................................................................33
Assembly ................................................................ 29 Inspection and Adjustment ......................................33
Installation ............................................................... 29 CLUTCH DISC .....................................................33
PIPING ....................................................................... 30 CLUTCH COVER AND FLYWHEEL ....................34
Removal ................................................................. 30 FLYWHEEL INSPECTION ...................................34
Installation ............................................................... 30 Installation ...............................................................34
CLUTCH RELEASE MECHANISM ........................... 31 SERVICE DATA AND SPECIFICATIONS (SDS) ......35
Components ........................................................... 31 Clutch Control System ............................................35
Removal ................................................................. 31 Clutch Master Cylinder ............................................35
Inspection After Removal ....................................... 31 Clutch Operating Cylinder .......................................35
Installation ............................................................... 32 Clutch Disc ..............................................................35
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 33 Clutch Cover ...........................................................35
Components ........................................................... 33 Clutch Pedal ............................................................35

CL-2
 PRECAUTIONS
[QG18DE]
PRECAUTIONS PFP:00001
A
Precautions ECS005RJ

● The recommended clutch system hydraulic fluid is brake fluid “DOT 3”.
● Do not reuse drained brake fluid. B
● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If any brake fluid
is splashed on painted areas, wash it away with water immediately.
● Use a flare nut wrench (commercial service tool) when CL
removing or installing the clutch hydraulic tubes.
● Use new brake fluid to clean or wash any parts of the clutch
master cylinder and operating cylinder. D
● Never use any type of mineral oil such as gasoline or kero-
sene to clean or wash any parts of the clutch system. It will
ruin the rubber parts of the hydraulic system. E

SBR686C
F

WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air. G

CL-3
 PREPARATION
[QG18DE]
PREPARATION PFP:00002

Special Service Tools ECS005RK

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
KV30101600 (New) Installing clutch cover and clutch disc
KV30101000 (Former) a: 15.9 mm (0.626 in) dia.
(J33213) b: 17.9 mm (0.705 in) dia.
Clutch aligning bar c: 40 mm (1.57 in)

NT641

ST20050240 Adjusting unevenness of diaphragm spring of

( — ) clutch cover
Diaphragm spring adjusting wrench a: 150 mm (5.91 in)
b: 25 mm (0.98 in)

S-NT404

KV32101000 Removing and installing spring pin

(J25689-A) a: 4 mm (0.16 in) dia.
Pin punch

S-NT410

Commercial Service Tools ECS005RL

Tool name Description

1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench a: 10 mm (0.39 in)

S-NT360

CL-4
 Symptom
Reference page

Clutch slips
Clutch noisy
Suspected parts (Possible cause)

Clutch pedal spongy

Clutch grabs/chatters

Clutch does not disengage

NVH Troubleshooting Chart

Clutch pedal (Inspection and adjustment) CL-7

1
1
Clutch line (Air in line) CL-7

2
1
Master cylinder piston cup (Damaged) CL-9

3
2
Operating cylinder piston cup (Damaged) CL-11

4
2
Engine mounting (Loose) EM-62, "Removal and Installation"

CL-5
Release bearing (Worn, dirty or damaged) CL-14

1
Clutch disc (Out of true)

5
Check each part in order. If necessary, repair or replace these parts.

Clutch disc (Runout is excessive)

5
2
Clutch disc (Lining broken)

5
Clutch disc (Dirty or burned) CL-17

5
Clutch disc (Oily)

5
2
2
Clutch disc (Worn out)

2
2

Clutch disc (Hardened)

2

Clutch disc (Lack of spline grease) CL-17

5
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

6 Diaphragm spring (Damaged)

3

Diaphragm spring (Out of tip alignment) CL-18

6
2
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

Clutch cover (Distortion)

7
4

Flywheel (Distortion) CL-18

5
[QG18DE]
PFP:00003

ECS005RM

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.

L
F

K
E
B
A

CL

H
D

M
 CLUTCH SYSTEM
[QG18DE]
CLUTCH SYSTEM PFP:30502

Components ECS005RN

WCL005

1. Clutch pedal bracket 2. ASCD clutch switch (if equipped) 3. Clutch interlock switch
4. Clutch pedal 5. Clutch master cylinder 6. Nipple
7. Clutch damper (not serviceable) 8. Clevis 9. Hose clamp
10. Reservoir hose 11. Reservoir tank 12. Reservoir cap
13. Clutch disc 14. Clutch cover 15. Withdrawal lever
16. Clutch lever 17. Spring pin 18. Release bearing
19. Operating cylinder 20. Clutch hose 21. Spacer
22. Release bearing spring 23. Clutch tube

CL-6
 CLUTCH SYSTEM
[QG18DE]
Inspection and Adjustment ECS005RO

CLUTCH PEDAL INSPECTION AND ADJUSTMENT A

1. Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch
pedal. B
a. If the pin is not free, check that the ASCD switch or pedal stop-
per bolt is not applying pressure to the clutch pedal causing the
pin to bind. To adjust, loosen the ASCD switch or pedal stopper CL
bolt lock nut and turn the ASCD switch or pedal stopper bolt.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats freely in the bore of D
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d. If the pin is still not free, remove the pin and check for deforma-
E
tion or damage. Replace the pin if necessary. Leave the pin
removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
F
a. With the clutch pedal clevis pin removed, manually move the
pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal,
pedal bracket, assist spring, bushing, etc.). Reassemble the G
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
WCIA0146E
H
3. Adjust the clearance “C” while fully depressing the clutch pedal
(with the clutch interlock switch) as shown.
I
Clearance "C" : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check the clutch hydraulic system components (clutch master
cylinder, clutch operating cylinder, Clutch withdrawal lever, J
clutch release bearing, etc.) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related
parts as necessary. K
b. If any hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "BLEEDING PROCEDURE" .
NOTE: L
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all of the air from the system.
M

SCL800

BLEEDING PROCEDURE
CAUTION:
Carefully monitor the fluid level at the clutch master cylinder during the bleeding operation.
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system.

CL-7
 CLUTCH SYSTEM
[QG18DE]
1. Top off the clutch master cylinder reservoir with the recom-
mended brake fluid "DOT 3". Then attach the additional supply
tank as shown.
CAUTION:
Do not to splash brake fluid on painted areas; it may cause
paint damage. If brake fluid is splashed on painted areas,
wash it away with water immediately.
2. Connect a transparent vinyl tube to the air bleeder valve as
shown.
3. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
4. Open the air bleeder valve with the clutch pedal fully depressed.

WCL008

5. Close the air bleeder valve and tighten to specification.

Air bleeder valve : 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 87 in-lb)
6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 3 through 6 above until no more air bubbles are in the brake fluid coming out of the vinyl
tube attached to the air bleeder valve.

CL-8
 CLUTCH MASTER CYLINDER
[QG18DE]
CLUTCH MASTER CYLINDER PFP:30610
A
Components ECS005RP

CL

G
WCIA0137E

1. Cylinder body 2. Return spring 3. Piston assembly seals

4. Push rod 5. Stopper 6. Stopper ring H
7. Dust cover 8. Clevis 9. Hose clamps
10. Reservoir hose 11. Reservoir cap 12. Reservoir tank
13. Bracket 14. Clutch damper (not serviceable) 15. Clutch tube I
16. Seal 17. Pin 18. Nipple

Removal ECS005RQ
J
1. Drain the brake fluid from the clutch hydraulic system.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
K
splashed on painted areas, wash it away with water immediately.
2. Remove the clutch tube flare nut using a flare nut wrench.
3. Remove the reservoir hose. L
4. Remove the snap pin from the clevis pin and remove the clutch pedal from the clevis.
5. Remove the master cylinder assembly mounting nuts and reservoir tank bracket mounting nuts to remove
master cylinder assembly. M
Disassembly ECS005RS

1. Loosen the push rod lock nut "A" to remove the clevis and the
lock nut "A".
2. Remove the dust cover.
3. Remove the stopper ring and stopper, then remove the push rod
from the cylinder body. During removal, keep the push rod
depressed, to prevent the piston inside the master cylinder from
popping out.
NOTE:
Discard the stopper ring and use a new ring for assembly.
4. Remove the piston assembly from the cylinder body. SCL725
5. Remove the return spring.
6. Remove the pin using a pin punch, then remove the nipple and seal.

CL-9
 CLUTCH MASTER CYLINDER
[QG18DE]
Inspection ECS005RT

Inspect for the following conditions and replace any parts as necessary.
● Damage, wear, rust, and pinholes on the cylinder inner wall
● Damage and deformation of the reservoir tank
● Weak return spring
● Crack or deformation of the dust cover
Assembly ECS005RU

1. Install the return spring.

2. Apply rubber lubricant to the sliding parts of the piston assembly, and insert the piston assembly into the
cylinder body.
3. After installing the stopper to push rod, install a new stopper ring while keeping the piston assembly
depressed by hand, so that the piston assembly will not pop out.
CAUTION:
The stopper ring cannot be reused. Always use a new stopper ring for assembly.
4. Apply silicone grease, and install the dust cover.
5. Install the clevis to push rod, and tighten lock nut "A" to specifi-
cation.
Lock nut "A" : 7.8 - 11.8 N·m (0.8 - 1.2 kg-m,
69 - 104 in-lb)
6. Install the seal and nipple to the cylinder body, and install the pin
using a pin punch.

SCL725

Installation ECS005RR

1. Install the reservoir hose.

2. Connect the clutch tube to the master cylinder assembly, and hand-tighten the flare nut.
3. Install the master cylinder assembly to the cowl, and tighten the mounting nuts to specification.
Master cylinder mounting nuts : 10.8 - 14.6 N·m (1.1 - 1.4 kg-m, 8 - 10 ft-lb)
4. Tighten the reservoir tank bracket mounting nuts to specification.
Reservoir tank bracket mounting nuts : 2.9 - 5.9 N·m (0.29 - 0.60 kg-m, 26 - 52 in-lb)
5. Tighten the clutch tube flare nut to specification, using a flare nut torque wrench.
Clutch tube flare nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
6. After installing the clevis pin, install the snap pin to connect the clutch pedal to the push rod.
7. After finishing the component installation, bleed the air from the clutch hydraulic system. Refer to CL-7,
"BLEEDING PROCEDURE" .

CL-10
 OPERATING CYLINDER
[QG18DE]
OPERATING CYLINDER PFP:30620
A
Components ECS005RV

CL

G
WCIA0138E

1. Cylinder body 2. Piston spring 3. Piston cup

4. Piston 5. Push rod 6. Dust cover H
7. Air bleeder 8. Spacer 9. Union bolt
10. Copper washer 11. Clutch hose

Removal ECS005RW
I

1. Drain the brake fluid from the clutch hydraulic system.

CAUTION: J
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
2. Remove the union bolt, the two copper washers, and the clutch
hose from the operating cylinder. Discard the copper washers. K
3. Remove the operating cylinder bolts, and remove the operating
cylinder.
L

WCL009

Disassembly ECS005RX

1. Remove the dust cover from the operating cylinder body.

2. Remove the push rod.
3. Remove the piston.
4. Remove the piston cup.
5. Remove the piston spring.
6. Remove the air bleeder.
Inspection ECS005RY

Inspect for the following, and replace any parts as necessary.

● Damage, foreign material, wear, rust, and pinholes on the cylinder inner surface, piston, and sliding part of
piston cup

CL-11
 OPERATING CYLINDER
[QG18DE]
● Weak piston spring
● Crack or deformation of dust cover
Assembly ECS005RZ

CAUTION:
To assemble the operating cylinder use the specified rubber grease and rubber lubricant. Refer to GI-
45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
1. Apply rubber lubricant to the overall inside surface of the operating cylinder body.
2. Install the air bleeder, tighten to specification.
Air bleeder : 6 - 10 N·m (0.6 - 1.0 kg-m, 52 - 87 in-lb)
3. Install the piston spring with the tapered spring end pointing toward the piston cup.
4. Apply rubber grease and install the piston cup.
5. Apply rubber grease and install the piston.
6. Install the push rod.
7. Apply rubber grease and install the dust cover.
Installation ECS005S0

Installation is in the reverse order of removal.

CAUTION:
● Install the clutch hose without twisting it.
● The two copper washers for the union bolt cannot be reused. Use two new copper washers for
installation.
● After finishing the installation, bleed the air from the clutch hydraulic system. Refer to CL-7,
"BLEEDING PROCEDURE" .

CL-12
 PIPING
[QG18DE]
PIPING PFP:00000
A
Removal ECS005S1

1. Remove the engine air cleaner and air duct. Refer to EM-13, "Removal and Installation" .
2. Drain the brake fluid from the clutch hydraulic system. B
CAUTION:
Be careful not to splash brake fluid on painted areas, it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately. CL
3. Remove the flare nut from the operating cylinder body using a flare nut wrench.
4. Remove the union bolt and two copper washers attaching the clutch hose from the operating cylinder. Dis-
card the two copper washers. D
5. Remove the clutch hose from the bracket by removing the lock plate.
Installation ECS005S2
E
1. When installing the clutch hose into the bracket, position the
lock plate in the specified direction as shown to secure the
clutch hose.
F
CAUTION:
Install the clutch hose without twisting or bending it.
2. Tighten the flare nut to specification, using a flare nut wrench.
G
Flare nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
CAUTION:
Be careful not to damage the flare nut and clutch tube. H
3. Position the clutch hose and install the union bolt and two new SCL730

copper washers on to the operating cylinder, and tighten the

union bolt to specification. I
Union bolt : 17 - 19 N·m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)
4. Bleed the air from the clutch hydraulic system. Refer to CL-7, "BLEEDING PROCEDURE" .
J
5. Install the engine air cleaner and air duct. Refer to EM-13, "Removal and Installation" .

CL-13
 CLUTCH RELEASE MECHANISM
[QG18DE]
CLUTCH RELEASE MECHANISM PFP:30502

Components ECS005S3

SCL819

Removal ECS005S4

1. Remove the manual transaxle. Refer to MT-15, "Removal and

Installation" (RS5F70A).
2. Move the withdrawal lever enough to remove the release bear-
ing and release bearing spring, and remove the release bearing
from the clutch lever.
3. Support the clutch lever claws with an appropriate wood block,
align the retaining pin with "A" as shown, and drive out the
spring pins using a pin punch.
4. Pull out the withdrawal lever and remove the clutch lever from
the clutch housing.
WCL018

Inspection ECS005S5

● Replace the release bearing if it is seized, damaged, faulty in

rotation direction, or has poor alignment.
● Replace the withdrawal lever if the contact surface is worn
excessively.
● Replace the clutch lever if its contact surface is worn exces-
sively.

SCL733

Installation ECS005S6

CAUTION:
● Apply grease to the clutch components. Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off completely, as it may cause the clutch
components to slip and shudder.
● Keep the clutch disc facing, pressure plate, and flywheel free of oil and grease.

CL-14
 CLUTCH RELEASE MECHANISM
[QG18DE]
● Clean any old grease and abrasive materials off of the
grease application areas as shown. A
● Apply approximately a 1 mm (0.04 in) thick coating of clutch
sleeve grease evenly on the sliding part of the clutch lever
and the release bearing spring. B
● Apply just enough clutch sleeve grease to fill up the release
bearing inner groove.
● Apply the clutch grease to the clutch disc and the input CL
shaft spline. Install the clutch disc to the input shaft,
remove the excess grease around the shaft, and remove the
clutch disc.
D
● Lightly and evenly apply the clutch sleeve grease on the
sliding part of the release bearing. Install the release bear-
ing and remove any excess grease around the bearing, then
remove the release bearing. E

G
SCL821

1. Assemble the clutch lever to clutch housing, and insert the withdrawal lever. H
2. Support the clutch lever claws with an appropriate wood block,
and install new spring pins using a pin punch as shown.
CAUTION: I
Spring pins cannot be reused.

K
WCL015

3. Install the release bearing springs on to the release bearing as

L
shown.

SCL736

CL-15
 CLUTCH RELEASE MECHANISM
[QG18DE]
4. Operate the withdrawal lever manually, press the release bear-
ing spring from both sides, and install the release bearing onto
the clutch lever securely.
CAUTION:
Make sure a click is heard when the release bearing spring
is pressed from both sides.

SCL823

5. Check that all parts operate smoothly when operating the with-
drawal lever.
CAUTION:
Remove any excess grease.

SCL738

6. Install the manual transaxle. Refer to MT-15, "Removal and Installation" (RS5F70A).

CL-16
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QG18DE]
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100
A
Components ECS005S7

CL

LCL049
G

Removal ECS0077Y

1. Remove the manual transaxle. Refer to MT-15, "Removal and Installation" (RS5F70A). H
2. Evenly loosen the clutch cover bolts, then remove the clutch cover and clutch disc.
Inspection and Adjustment ECS005S8
I
CLUTCH DISC
● Check the clutch disc for wear on the facing surface at the rivets
as shown.
J
Wear limit of facing surface to rivet head : 0.3 mm
(0.012 in)
K

LCL050

● Check the clutch disc for backlash on the spline and runout on M
the facing.
Maximum backlash of spline : 0.9 mm (0.035 in)
(at outer edge of disc)
Runout limit : 1.0 mm (0.039 in)
Distance of runout check point : 102.5 mm (4.04 in)
(from hub center)

LCL051

● Check the clutch disc for burns, discoloration, and oil or grease leakage. Replace if necessary.

CL-17
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QG18DE]
CLUTCH COVER AND FLYWHEEL
● Check the clutch cover installed for unevenness of the dia-
phragm spring toe heights.
Uneven limit : 0.88 mm (0.0346 in)
If the toe heights are greater than the uneven limit, adjust the
height with Tool as shown.

WCL016

FLYWHEEL INSPECTION
● Check the contact surface of flywheel for slight burns or discoloration. Clean the flywheel contact surface
with emery paper.
● Check the flywheel runout using a dial gauge as shown.
Maximum allowable : Refer to EM-76, "Flywheel
runout Runout" .

SCL349

Installation ECS005S9

Installation is in the reverse order of removal.

CAUTION:
● Do not clean the clutch disc with solvent.
● When installing the clutch disc, do not to allow grease from the main driveshaft to contact the
clutch disc friction surface.
● Insert Tool into clutch disc hub for proper alignment when install-
ing the clutch cover and disc as shown.
● Tighten the clutch cover bolts in numerical order in two steps as
shown.
First step : 10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-lb)
Final step : 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-lb)

WCL017

CL-18
 SERVICE DATA AND SPECIFICATIONS (SDS)
[QG18DE]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Clutch Control System ECS005SA

Type of clutch control Hydraulic

B
Clutch Master Cylinder ECS005SB

Unit: mm (in)
Inner diameter 15.87 (5/8) CL
Clutch Operating Cylinder ECS005SC

Unit: mm (in)
D
Inner diameter 19.05 (3/4)

Clutch Disc ECS005SD

Unit: mm (in) E
Engine model QG18DE
Model 215
F
Facing size (Outer dia. × inner dia. × thickness) 215 × 145 × 3.5 (8.46 × 5.71 × 0.138)
7.7 - 8.3 (0.303 - 0.327)
Thickness of disc assembly with load
with 4,900 N (499.8 kg, 1,101.5 lb)
G
Wear limit of facing surface to rivet head 0.3 (0.012)
Runout limit of facing 1.0 (0.039)
Distance of runout check point (from the hub center) 102.5 (4.04) H
Maximum backlash of spline (at outer edge of disc) 0.9 (0.035)

Clutch Cover ECS005SE I

Unit: mm (in)
Engine model QG18DE
Model 215 J
Full-load 4,900 N (499.8 kg, 1,101.5 lb)
Uneven limit of diaphragm spring toe height 0.88 (0.0346)
K
Clutch Pedal ECS005SF

Unit: mm (in)
Clearance “C” between pedal stopper rubber and clutch interlock switch threaded end L
0.1 - 1.0 (0.004 - 0.039)
while clutch pedal is fully depressed.

CL-19
 PRECAUTIONS
[QR25DE]
PRECAUTIONS PFP:00001

Precautions ECS005SG

● Recommended fluid is brake fluid “DOT 3”.

● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
● Use a flare nut wrench when removing or installing the
clutch hydraulic tubes.
● Use new brake fluid to clean or wash all parts of the master
cylinder and operating cylinder.
● Never use mineral oils such as gasoline or kerosene. It will SBR686C
ruin the rubber parts of the hydraulic system.

WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air.

CL-20
 PREPARATION
[QR25DE]
PREPARATION PFP:00002
A
Special Service Tools ECS005SH

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
ST20630000 Installing clutch cover and clutch disc
(J26366) a: 15.8 mm (0.622 in) dia. CL
Clutch aligning bar b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)

NT405

ST20050240 Adjusting unevenness of diaphragm spring of E

( — ) clutch cover
Diaphragm spring adjusting wrench a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
F

S-NT404
G
KV32101000 Removing and installing spring pin
(J25689-A) a: 4 mm (0.16 in) dia.
Pin punch
H

S-NT410
I

Commercial Service Tools ECS005SI

Tool name Description J

1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench a: 10 mm (0.39 in)
K

L
S-NT360

CL-21
 Symptom
Reference page

Clutch slips
Clutch noisy
Suspected parts (Possible cause)

Clutch pedal spongy

Clutch grabs/chatters

Clutch does not disengage

NVH Troubleshooting Chart

Clutch pedal (Inspection and adjustment) CL-24

1
1
Clutch line (Air in line) CL-24

2
1
Master cylinder piston cup (Damaged) CL-26

3
2
Operating cylinder piston cup (Damaged) CL-28

4
2
Engine mounting (Loose) EM-62, "Removal and Installation"

CL-22
Release bearing (Worn, dirty or damaged) CL-31

1
Clutch disc (Out of true)

5
Check each part in order. If necessary, repair or replace the parts.

Clutch disc (Runout is excessive)

5
2
Clutch disc (Lining broken)

5
Clutch disc (Dirty or burned) CL-33

5
Clutch disc (Oily)

5
2
2
Clutch disc (Worn out)

2
2

Clutch disc (Hardened)

2

Clutch disc (Lack of spline grease) CL-33

5
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

6 Diaphragm spring (Damaged)

3

Diaphragm spring (Out of tip alignment) CL-34

6
2
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

Clutch cover (Distortion)

7
4

Flywheel (Distortion) CL-34

5
[QR25DE]
PFP:00003

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
ECS005SJ
 CLUTCH SYSTEM
[QR25DE]
CLUTCH SYSTEM PFP:30502
A
Components ECS005SK

CL

WCIA0139E

1. Reservoir cap 2. Hose clamp 3. Reservoir tank

4. Reservoir hose 5. Clutch tube 6. Nipple
7. Clutch master cylinder 8. Clevis 9. Clutch pedal bracket
10. Clutch interlock switch 11. ASCD clutch switch (if equipped) 12. Clutch pedal
13. Clutch cover 14. Withdrawal lever 15. Spacer
16. Clutch lever 17. Spring pin 18. Release bearing spring
19. Release bearing 20. Clutch hose 21. Operating cylinder
22. Clutch disc

CL-23
 CLUTCH SYSTEM
[QR25DE]
Inspection and Adjustment ECS006H9

CLUTCH PEDAL INSPECTION AND ADJUSTMENT

1. Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch
pedal.
a. If the pin is not free, check that the ASCD switch or pedal stop-
per bolt is not applying pressure to the clutch pedal causing the
pin to bind. To adjust, loosen the ASCD switch or pedal stopper
bolt lock nut and turn the ASCD switch or pedal stopper bolt.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats freely in the bore of
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d. If the pin is still not free, remove the pin and check for deforma-
tion or damage. Replace the pin if necessary. Leave the pin
removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
a. With the clutch pedal clevis pin removed, manually move the
pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal,
pedal bracket, assist spring, bushing, etc.). Reassemble the
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
WCIA0146E

3. Adjust the clearance “C” while fully depressing the clutch pedal
(with the clutch interlock switch) as shown.
Clearance "C" : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check the clutch hydraulic system components (clutch master
cylinder, clutch operating cylinder, Clutch withdrawal lever,
clutch release bearing, etc.) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related
parts as necessary.
b. If any hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-24, "BLEEDING PROCEDURE" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all of the air from the system.

SCL800

BLEEDING PROCEDURE
CAUTION:
Carefully monitor the fluid level at the clutch master cylinder during the bleeding operation.
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system.

CL-24
 CLUTCH SYSTEM
[QR25DE]
1. Top off the clutch master cylinder reservoir with the recom-
mended brake fluid "DOT 3". Then attach the additional supply A
tank as shown.
CAUTION:
Do not to splash brake fluid on painted areas; it may cause B
paint damage. If brake fluid is splashed on painted areas,
wash it away with water immediately.
2. Connect a transparent vinyl tube to the air bleeder valve as
CL
shown.
3. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals. D
4. Open the air bleeder valve with the clutch pedal fully depressed.

G
WCL008

5. Close the air bleeder valve and tighten to specification.

H
Air bleeder valve : 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 87 in-lb)
6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 3 through 6 above until no more air bubbles are in the brake fluid coming out of the vinyl I
tube attached to the air bleeder valve.

CL-25
 CLUTCH MASTER CYLINDER
[QR25DE]
CLUTCH MASTER CYLINDER PFP:30610

Components ECS005SM

WCIA0140E

1. Bracket 2. Reservoir cap 3. Reservoir tank

4. Hose clamps 5. Reservoir hose 6. Nipple
7. Piston assembly seals 8. Push rod 9. Stopper ring
10. Stopper 11. Dust cover 12. Clevis
13. Return spring 14. Pin 15. Seal
16. Cylinder body 17. Clutch tube

Removal ECS005SN

1. Drain the brake fluid from the clutch hydraulic system.

CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
2. Remove the clutch tube flare nut using a flare nut wrench.
3. Remove the reservoir hose.
4. Remove the snap pin from the clevis pin and remove the clutch pedal from the clevis.
5. Unscrew the master cylinder assembly nuts and reservoir tank bracket nuts to remove the master cylinder
assembly.
Disassembly ECS005SP

1. Loosen the push rod lock nut "A" to remove the clevis and lock
nut "A".
2. Remove the dust cover.
3. Remove the stopper ring and stopper, and remove the push rod
from the cylinder body. During removal, keep the push rod
depressed, to prevent the piston inside the master cylinder from
popping out. Discard the stopper ring.
4. Remove the piston assembly from the cylinder body.
5. Remove the return spring.
6. Remove the pin using a pin punch, then remove the nipple and SCL725
seal.
Inspection ECS005SQ

Inspect for the following, and replace parts if necessary.

CL-26
 CLUTCH MASTER CYLINDER
[QR25DE]
● Damage, wear, rust, and pinholes on the cylinder inner wall
● Damage and deformation of the reservoir tank A
● Weak spring
● Crack or deformation of the dust cover
B
Assembly ECS005SR

1. Install the return spring.

2. Apply rubber lubricant to the sliding parts of the piston assembly, and insert the piston assembly into cylin- CL
der body.
3. After installing the stopper on to the push rod, install the new stopper ring while keeping the piston assem-
bly depressed by hand, so that the piston assembly will not pop out. D
CAUTION:
The stopper ring cannot be reused. Always use a new stopper ring for assembly.
4. Apply silicone grease to the dust cover and install the dust cover. E
5. Install the clevis on to push rod, and tighten the lock nut "A" to
specification.
F
Lock nut "A" : 7.8 - 11.8 N·m (0.8 - 1.2 kg-m,
69 - 104 in-lb)
6. Install the seal and nipple on to the cylinder body, and install the G
pin using a pin punch.

H
SCL725

Installation ECS005SO
I
1. Install the reservoir hose.
2. Connect the clutch tube to the master cylinder assembly, and hand-tighten the flare nut.
3. Install the master cylinder assembly to the cowl, and tighten the nuts to specification. J

Master cylinder nuts : 10.8 - 14.6 N·m (1.1 - 1.4 kg-m, 8 - 10 ft-lb)
4. Tighten reservoir tank bracket nuts to specification. K
Reservoir tank bracket nuts : 2.9 - 5.9 N·m (0.29 - 0.60 kg-m, 26 - 52 in-lb)
5. Tighten clutch tube flare nut using a flare nut torque wrench to specification. L
Clutch tube flare nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
6. After installing the clevis pin, install the snap pin to connect the clutch pedal to the push rod.
M
7. After finishing the installation, bleed the air out of the clutch hydraulic system. Refer to CL-24, "BLEEDING
PROCEDURE" .

CL-27
 OPERATING CYLINDER
[QR25DE]
OPERATING CYLINDER PFP:30620

Components ECS005SS

WCIA0141E

1. Cylinder body 2. Piston spring 3. Piston cup

4. Piston 5. Push rod 6. Dust cover
7. Air bleeder 8. Union bolt 9. Copper washer
10. Clutch hose

Removal ECS005ST

1. Drain the brake fluid from clutch hydraulic system.

CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
2. Remove the union bolt, the two copper washers, and the clutch
hose from the operating cylinder. Discard the copper washers.
3. Remove the operating cylinder bolts, and remove the operating
cylinder.

LCIA0029E

Disassembly ECS005SU

1. Remove the dust cover from the operating cylinder body.

2. Remove the push rod.
3. Remove the piston.
4. Remove the piston cup.
5. Remove the piston spring.
6. Remove the air bleeder.
Inspection ECS005SV

Inspect for the following, and replace parts as necessary.

● Damage, foreign material, wear, rust, and pinholes on the cylinder inner surface, piston, and sliding part of
piston cup

CL-28
 OPERATING CYLINDER
[QR25DE]
● Weak piston spring
● Crack or deformation of dust cover A

Assembly ECS005SW

1. Apply rubber lubricant to the overall inside surface of the operating cylinder body. B
CAUTION:
To assemble the operating cylinder use the specified rubber grease and rubber lubricant. Refer to
GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CL
2. Install the air bleeder and tighten to specification.
Air bleeder : 6 - 10 N·m (0.6 - 1.0 kg-m, 52 - 87 in-lb)
D
3. Install the piston spring.
4. Apply rubber grease and install the piston cup.
5. Apply rubber grease and install the piston. E
6. Install the push rod.
7. Apply rubber grease and install the dust cover.
Installation ECS005SX
F

Installation is in the reverse order of removal.

CAUTION: G
● Install the clutch hose without twisting it.
● The two copper washers for the union bolt cannot be reused. Use two new copper washers for
installation. H
● After finishing the installation, bleed the air from the clutch hydraulic system. Refer to CL-24,
"BLEEDING PROCEDURE" .
I

CL-29
 PIPING
[QR25DE]
PIPING PFP:00000

Removal ECS005SY

1. Remove the engine air cleaner and air duct. Refer to EM-101, "Removal and Installation" .
2. Drain the brake fluid from the clutch hydraulic system.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
3. Remove the flare nut from the operating cylinder body using a flare nut wrench.
4. Remove the union bolt and two copper washers attaching the clutch hose from the operating cylinder. Dis-
card the two copper washers.
5. Remove the clutch hose from the bracket by removing the lock plate.
Installation ECS005SZ

1. When installing the clutch hose into the bracket, position the
lock plate in the specified direction as shown to secure the
clutch hose.
CAUTION:
Install the clutch hose without twisting or bending it.
2. Tighten the flare nut to specification, using a flare nut wrench.
Flare nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
CAUTION:
Be careful not to damage the flare nut and clutch tube.
3. Position the clutch hose and install the union bolt and two new SCL730

copper washers on to the operating cylinder, and tighten the

union bolt to specification.
Union bolt : 17 - 19 N·m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)
4. Bleed the air from the clutch hydraulic system. Refer to CL-24, "BLEEDING PROCEDURE" .
5. Install the engine air cleaner and air duct.

CL-30
 CLUTCH RELEASE MECHANISM
[QR25DE]
CLUTCH RELEASE MECHANISM PFP:30502
A
Components ECS005T0

CL

LCIA0030E
G

Removal ECS005T1

1. Remove the manual transaxle. Refer to MT-79, "Removal and Installation" (RS6F51H). H
2. Move the withdrawal lever enough to remove the release bearing, and remove the release bearing from
the clutch lever.
3. Remove the withdrawal lever retainer spring. I
4. Pull out the withdrawal lever and remove the dust cover.
Inspection After Removal ECS005T2
J
● Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor alignment.
● Replace the withdrawal lever if the contact surface is worn K
excessively.
● Replace the dust seal if its deformed or cracked.
L

M
SCL733

CL-31
 CLUTCH RELEASE MECHANISM
[QR25DE]
Installation ECS005T3

Installation is in the reverse order of removal.

● Clean any old grease and abrasive materials off of the grease application areas as shown.

SCL815

● Apply approximately a 1 mm (0.04 in) thick coating of clutch sleeve grease to the withdrawal lever and
holder spring friction surfaces.
● Apply a coat of clutch sleeve grease to the grooves on contact surfaces of the withdrawal lever ball pin
and inner surface of the release bearing; make sure the grease is flush with the grooves.
● Apply a thin coat of clutch sleeve grease to the release bearing friction surface. After the grease applica-
tion, install the release bearing. Wipe off any excess grease forced out from the bearing installation.

CL-32
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QR25DE]
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100
A
Components ECS005T4

CL

G
WCIA0142E

1. Flywheel 2. Clutch disc 3. Washer

4. Main drive shaft 5. Clutch cover H
Removal ECS0077Z

1. Remove the transaxle. Refer to MT-79, "Removal and Installation" (RS5F51H).

I
2. Evenly loosen the clutch cover bolts, then remove the clutch cover and clutch disc.
Inspection and Adjustment ECS005T5

CLUTCH DISC J
● Check clutch disc for wear of the facing surface at the rivets as
shown.
Wear limit of facing surface to rivet head : 0.3 mm K
(0.012 in)

M
LCIA0109E

● Check the clutch disc for backlash of the spline and runout of the
facing as shown.
Maximum backlash of spline : 0.9 mm (0.035 in)
(at outer edge of disc)
Runout limit : 1.0 mm (0.039 in)
Distance of runout check point : 115.0 mm (4.53 in)
(from hub center)

LCIA0108E

● Check the clutch disc for burns, discoloration, or oil and grease leakage. Replace the components as nec-
essary.

CL-33
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QR25DE]
CLUTCH COVER AND FLYWHEEL
Check the spring toe height unevenness of the clutch cover with it
installed on the vehicle.
Uneven limit : 0.7 mm (0.028 in)
If the measured uneven height is greater than the specified limit,
adjust the spring toe height with Tool as shown.

WCL016

FLYWHEEL INSPECTION
● Check the contact surface of the flywheel for slight burns or discoloration. Clean the flywheel contact sur-
face with emery paper.
● Check the flywheel runout using a dial gauge as shown.
Maximum allowable : Refer to EM-183, "MOVEMENT
runout AMOUNT OF FLYWHEEL (M/T
MODEL)" .

SCL349

Installation ECS005T6

Installation is in the reverse order of removal.

CAUTION:
● Do not clean the clutch disc with solvent.
● When installing the clutch disc, do not allow grease from the main driveshaft to contact the clutch
disc friction surface.
● Insert Tool into the clutch disc hub for correct alignment when
installing the clutch cover and disc as shown.
● Tighten the bolts in numerical order in two steps as shown.
First step : 10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-lb)
Final step : 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)

SCL600-C

CL-34
 SERVICE DATA AND SPECIFICATIONS (SDS)
[QR25DE]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Clutch Control System ECS005T7

Type of clutch control Hydraulic

B
Clutch Master Cylinder ECS005T8

Unit: mm (in)
Inner diameter 15.87 (5/8) CL
Clutch Operating Cylinder ECS005T9

Unit: mm (in)
D
Inner diameter 19.05 (3/4)

Clutch Disc ECS005TA

Unit: mm (in) E
Engine model QR25DE
Model 240
F
Facing size (Outer dia. × inner dia. × thickness) 240 × 160 × 3.5 (9.45 × 6.30 × 0.138)
7.8 - 8.4 (0.307 - 0.331)
Thickness of disc assembly with load
with 5,884 N (600 kg, 1,322 lb)
G
Wear limit of facing surface to rivet head 0.3 (0.012)
Runout limit of facing 1.0 (0.039)
Distance of runout check point (from the hub center) 115.0 (4.53) H
Maximum backlash of spline (at outer edge disc) 0.9 (0.035)

Clutch Cover ECS005TB I

Unit: mm (in)
Engine model QR25DE
Model 240 J
Full-load 5,884 N (600 kg, 1,322 lb)
Uneven limit of diaphragm spring toe height 0.7 (0.028)
K
Clutch Pedal ECS005TC

Unit: mm (in)
Clearance “C” between pedal stopper rubber and clutch interlock switch threaded end L
0.1 - 1.0 (0.004 - 0.039)
while clutch pedal is fully depressed.

CL-35
SERVICE DATA AND SPECIFICATIONS (SDS)
[QR25DE]

CL-36