clutch DATSUN 210 1979 User Guide

INSPECTION

Entire

system

U
S
A
MIT

models

except
FU
mo

el

1
Ensure
that

wiring
connectors
are

tight
in

pla
ce

2
Ensure
that

vacuum
hoses

are

properly

cof
1o
c
ed
to

their

positions

3
Ensure
that
distributor
vacuum

controller

properly
functions

4

Set

timing
light
and
start

engine

S

While

engine
cooling
water
tem

pefature
is
below

SOOC

I220F

check
function
of

system
as
follows

WARNING

To

protect
against
accidental
for

ward

surge
engage

parking
brake

firmly
while
above
check
is

being

made

I
Run

engine
and

keep
it

at

ap

proximately
1
600

rpm

2

Disengage
clutch
Shift

gears
in

top
3rd
then
neutral

positions
Read

spark

timing
in

respective
shift

posi

tions

The

system
is

properly

functioning

if

spark
timir
g
does
not

change

If
t

changes
check
thefmal
vacuum

valve

3

port
type

Note

Ensure
that
thermal
vacuum

wIve

is
closed
when

cooling
water

i
below

5
to
lSoC
41
to

640F
or

above
SO

to
630C
122
to
14S0F

I

6

After
the

engine
has
been

warmed

up
sufficiently
check
the

function
of
the

system

again
in
the

I

Same
manner

The

system
is

properly
functioning

if

spark
iimin
advances
in

top
posi

tion

If

not
check
thefmal
vacuum
valve

control

circuit
or
vaeu
um

switching

valve

Entire

system

FU
model
and

Canada
MIl
models

I
Ensure
that

wiri
lg
connectors
are

tight
in

place
Emission

Control

System

2

Ensure
that

vacuum

hoses
are

properly
connected
to
their

positions

3

Ensure
that

distributor
vacuum

controller

properly
fu
ctions

4

Set

timing
light

WARNING

To

protect

against
accidental
for

ward

surge
engage
parking
brake

firmly
while
above
check

is

being

made

5
Run

engine
and

keep
it
at

ap

proximately
1
600

1
m

6

Disengage
clutch
Shift

gears
in

4th

5th
ihen
neutral

positions
Read

spark
timing
in

respective
shift

posi

tions

The

system
is

properly
functioning

if

spark
timing
advances
in

top
gear

position

If

spark

timing
does
not

vary
at
all

in

tests
des
rilied

in

step
6
above

check

control
circuit
or

vacuum

switching
valve

Entire

system

California
AIT
models

I
Ensure
th
t

wiring
connectors

are

tight
in

place

2

Ensure
that
vacuum
hoses
are

properly
coIDwcted
to

thejr
positions

3

Ensure
that

distributor
vacuum

controller

function
s

properly

4
Set

timing
light
and
staft

engine

S

While

engine
cooling
water
tem

perature
is
below
SOOC
1220F

check
the
function
of
the

system
as

follows

WARNING

To

protect
againSt
accidental
for

ward

surge
engage

parking
brake

firmly
while
above
check
is

being

made

I
Run

engine
and

keep
it
at

ap

proximately
1

600

rpm
at
P

range

2

Make
a

short
circuit

between
the

specified
two
terminals
at
function

te
t

connector

EC31
The

entire

system

except
for
the

top
switch
is

properly

functioning
if

spark
timing
does
not

change
If

it

changes
check
the

thermal
vacuum

valve

3

pori

type

CAUTION

Pay
attention
not
to
make
a
short

circuit
between
other
terminals
than

the

specified
terminals
or
electrical

system
of
car
will

get

damaged

4

EC328A

Fig
EC
94

Making
Short
Circuit

6

After
ihe

engine
has
been

warmed

up
sufficiently
check
the

function
of
the

system
again
in
the

same
manner

The

system
except
for
the

top

switch
is

properly

fU
lctioning
if

spark

timing
is

approximately
greater
than

that
without

a
short
circuit

If

not
check
the

thermal
vacuum

valve

control
circuit
or

vacuum
switch

ing
valve

7
As
the
final

step
of

checking

entire

system
top
switch
should
be

checked

as
follows

1
Start

engine
and

keep
at

idling

speed

2

Disconnect
lead
wires
from
vacu

um

switching
valve

at
connetors

CAUTION

Never

forget
this

operation
otherwise

the
circuit

tester
will

get
damaged

REMOVAL
AND

INSTALLATION

Disconnect

battery
ground
cable

Disconnect
harness

connector
and

battery
cable

at

magnetic
switch

2
Remove

bolts

securing
starting

motor
to
transmission

case
Pull

start

iog
motor

forward
and

remove
it

3
Inst
1I

starting
motor
in

reverse

order
of

removal

DISASSEMBLY

NON
REDUCTION
GEAR

TYPE

I
Disconnect

connecting
plate
from

M

terminal
of

magnetic
switch
Re

move
two

screws

securing
magnetic

switch
and
remove

magnetic
switch

assembly

2
Remove

dust
cover
E

ring
and

thrust
washer
s

EE311
@@

O

Fig
EE

8
Removing
DUll
Cover

E

ring
and
ThrUJJt

Washer

3
Remove
two
screws

securing

brush
holder

assembly

EE318

Fig
EE

9
Removing
Bru
h
Hold

Setacrews
Engine
Electrical

ystem

4
Remove
two
ihrough
bolts
and

rear
cover

5
Remove

brushes
from
their

hold

er

by
moving
each
brush

spring
away

from
brush
with
a
hook

Remove

brush
holder

6
Remove

yoke
assembly
and
with

draw

armature
assembly
and
shift

lever

7
Remove

pinion
stopper
located
at

the
end
of
armature
shaft
To
remove

stopper
first
move

stopper
toward

pinion
and
after

removing
stopper
clip

remove

stopper
with

overruniling

clutch
assembly
from
armature
shaft

EE271

Fig
EE

lg
Rf

moving
Pinion

Stopper

REDUCTION
GEAR
TYPE

1

Disconnect

connecting
plate
from

M
terminal
of

magnetic
switch
Re

move
two
screws

securing
magnetic

switch
and
remove

magnetic
switch

assembly

Note

Torsion

spring
can
be

pulled
off

magnetic
switch

2
Remove

through
baIts
and
rea

cover

Note

Rear
cover
can
be

pried
off
with

a
f1at
blade
screwdriver
inserted
be

tween
it

and

yoke
Be

careful
not

to
damage

packing
while

removing

reaf
cover

3
Remove

yoke
armature
and

brush
holder
as

an
assembly
from

center

housing

CAUTION

When

removing
be
careful
not
to

knock
brush
commutator
or
coil

against
any
adjacent
part

EE
6
o

7

EE615

Fig
EE
ll

Removing
Yo
and

Armature

4
To

remove
brush
holders

proceed

as
follows

I
Remove

brush
on

positive
side

from
its
holder

Note
Brush
on

positive
side
differs
in

that
it
is
isolated
from
brush
holder

and
its

lead
wire
is
connected
to

field
coil

2

Carefully
lifting
brush
on

nega

tive
side

away
from
commutator
sur

face
remove
it

from
brush
holder

EE616

Fig
EE
12

Removing
Br
h

5
Remove
bolts

securing
center

housing
to

gear
case
and
detach
center

housing

6
Remove

pinion

gear

CLEANING
AND

INSPECTION

Clean

all
disassembled

parts
but
do

not
use

grease
dissolving
solvents
for

cleaning
overrunning
clutch
armature

assembly
magnetic
switch

assembly

and
field
coils
since
such
a

solvent

would
dissolve

grease
packed
in
clutch

mechanism
and
would

damage
coils
or

other
insulators

Check
them
for
excessive

damage

or
wear
and

replace
if

necessary

2

Inspect
silldered
conneetibn
of

armature

lead
and

commutator
If

loose
connection
is
found

solder
it

using
resin
flux

3
Armature
test

for

ground

Using
a

circuit
tester

place
one
test

probe
onto
armature
core
or
shaft
and

other
onto
each

commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

L
L

I

EE022

F
EE
17

Teating
Armature

for

Ground

4
Check

armature
for
short

by
plac

ing
it
on

armature
tester

growler

with
a

piece
of
iron

over
arma
t
ure

core

rotating
armature
If
the

plate

vibrates
armature
is

shorted

jeBel

EE023

Fig
EE

18

Testing
Armature
or

Short

5

Check
armature
for

continuity
by

placing
probes
of
tester
on
two

seg

ments
side

by
side
If
tester
shows
no

continuity
the
circuit

is

open

OVERRUNNING
CLUTCH

ASSEMBLY

Inspect
pinion
assembly
and
screw

sleeve
or

reduction

gear
Screw
sleeve

must
slide

freely
along
armature
shaft

splines
or

pinion

gear
shaft
must
slide

freely
through
reduction

gear
If

dam

age
is
found
or
resistance

except
nor

mal
resistance
due
to

spring
felt

when

sliding
it

must
be

repaired

Inspect

pinion
teeth
If
excessive

rubbing
is

found
on

teeth

replace
Flywheel
ring

gear
also
must
be

inspected
Engine
Electrical

System

@

ll

EE278

Fig
EE
19

Overrunning
Clutch

Assembly

1
Pinion

gear

2

Reduction

gear

EE617

Fig
EE
20
Pinion
and

Reduction

Gear

Overrunni11C
Clutch

AS5em

bly

BRUSH
HOLDER
TEST

FOR

GROUND

Using
a

circuit
tester

place
one
test

probe
onto

negative
side
of
brush

holder
and
another
onto

positive
side

If

tester
shows

continuity
brush
hold

er

is
shorted
to

ground
Replace
brush

holder

EE025

Fig
EE

21

Testing
Brush

for

Ground

BEARING
METAL

Non
reduction

gear
type

spect
bearing
metal
for

wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm

0
008
in

replace

metal

EE

8
BAI
L

BEARING

Reduction

gear
type

Holding
outer
race
with

finger

rotate

bearing
to
see
if
there
is

any

play
or
bind
If

necessary
replace

bearing

MAGNETic

SWITCH

ASSEMBLY

I

Using
a
circuit
tester

check
con

tinuity
between
S

terminal
of

mag

netic
switch
and

switch

body
metal

If

continuity
does
not
exist

shunt
coil
is

opened

Replace
switch

assembly

2
In
the

same
manner
as
above

check

continuity
between
terminals

S
and
M

If

continuity
does
not

exist
series
coil
is

opened

Replace
switch

assembly

ASSEMBLY

Reassemble

starting
motor
in
re

verse

sequence
of

disassembly

When

assembling
be
sure
to

apply

grease
to

gear
case

and
rear
cover

bearing
metal
and

apply
oil

lightly
to

pinion

TEST

PERFORMANCE
TEST

Starter
motor
should
be

subjected

to
a
no
load
test
whenever
it

has

been

overhauled

to
ensure
that

its

perfo
rmance
will
be

satisfactory
when

installed
on

engine
Starter
motor

should
also
be

subjected
to
the
test

when
the

cause
of
abnormal

operation

is

to
be
determined
A
brief
outline
of

the
test
is

given
below

No

loadtest

Connect

starting
motor
in
series

willi

specified
12
volts

battery
and

an
ammeter

capable
of

indicating

1

000

amperes

Specified
current
draw
and
rev6lu

tion
in
this
test
are
shown
in

Sp
ci

Cications

REMOVAL

It
is
much
easier

to
remove

engine

and
transmission

as
a
single
unit
than

to

remove
alone
After
removal

engine

can
be

separated
from
the
transmission

assembly

WARNING

a
Place
wheel
chocks
in
fronl

of

front

wheels
and
in

rear
of

rear

wheels

b
Be
sure
to
hoist

engine
in
a
safe

manner

c
You
should
not
remove

engine

until
exhaust

system
has
com

pletely
cooled
off

Otherwise

you
may
burn

your

self
and
or
fire

may
break

out
in

fuel
line

Note
Fender
coven
should
be

used

to

protect
car

body

1
Disconnect

battery
ground
cable

from

battery
terminal
and
fusible
link

at
wire

connector

2
Remove
hood

as
follows

CAUTION

Have
an
assistant

help
you
so
as
to

prevent

damage
to

body

I
Mark
hood

hinge
locations
on

hood
to
facilitate
reinstallation

2

Support
hood

by
ltand
and
re

move
bolts

securing
it

to
hood

hinge

being
careful
not
to
let
hood

slip
when

bolts
are

removed
See

Fig
ER
2

3
Remove
hood
from
hood

hinge

f

Il

I

BF133A

Fig
ER
2

Removing
Hood

Remove

under
cover

Drain

radiator
coolant
and

engine
3

4

oil

5

Disconnect

upper
and
lower
hoses

from
radiator
and
disconnect
oil

cooler
hoses
automatic
transmission

only

6
Remove
four
bolts

securing
radia
Engine
Removal
Installation

tor

to

body
and
detach
radiator
after

removing
radiator
shroud

7

Remove
air
cleaner

assembly

from
carburetor
as
follows

1
Remove

fresh
air
duct
from
air

cleaner

2
Remove
hot
air
duct
from
air

cleaner

3

Loosen
air
cleaner
band
bolt

4
Disconnect
air

cleaner
to
air

pump
hose

at
air
cleaner

5

Disconnect
air
cleaner

ta
rocker

cover
hose

at
rocker
cover

6
Disconnect
air

cleaner
to
A
B

valve
hose
at
air

cleaner

7
Disconnect
air
cleaner
to
related

vacuum
hoses
at
air

cleaner

8
Disconnect
accelerator
control

wire
from
carburetor

9
Disconnect

the

following
cables

wires

and
hoses

Wire

to
auto
choke
heater

Wire
to

throttle

opener
cut
solenoid

or

throttle
switch

Wire

to
fuel
cut
solenoid

Wire
to

vacuum
switching
valve

High
tension

cable
between

igni

tion
coil
and
distributor

Battery
cable
to
starter
motor

Wire
to
distributor

Wire

to
thermal
transmitter

Wire

to
alternator

Engine
ground
cable
oil

pressure

switch
and

engine
harness
No
2

See

Fig
ER
3

o

1
Ground
cable

2

Engine
harness
No

2

3
Oil

pressure
switch

Fig
ER

3
EA368

Disconnecting
Cable
and

Wire

Fuel
hose

at
fuel

pump
and
fuel

return

hose
at
connection

Air

pump
air

cleaner
hose

Carbon
canister
hoses

Heater
inlet
and
outlet
hoses
if

so

equipped

ER
3
Vacuum
hose
of

brake
booster
at

intake
manifold

Air
conditioner

equipped

model

10
Remove

compressor
belt

To

remove
loosen
idler

pulley
nut

and

adjusting
bolt

1
Remove
air

pump

2
Remove

compressor
retaining

bolts
and
move

compressor
toward

fender
to
facilitate
removal
of

engine

Nole
Never

discharge
gas
from
com

pressor
while
work
is

being

per

formed

II

Compressor

EA478

Fig
ER
4

Location

of
Air

Compressor

3
Disconnect
vacuum
hose
of
air

conditioner
from
connector
of
intake

manifold

4
Remove

F
i

C
D

actuator
from

bracket

II
Remove
clutch

operating
cylin

der
from
clutch

housing
manual
trans

mission

only

dJ

Tightening
torque

Clutch

operating
cylinder

E
A3

to
clutch

housing

3
1

to
4
1

kg

22
to

30
ft
lbl

Fig
ER
5

Removing
Clutch

Operating

Cylinder

INSTALLATION

Install
in
the

reverse
order

of
re

moval

observing
the

following

Note

When

inslal1ing
be
sure
to

check
thaI
electrical
harnesses

are

connected
ly

1
When

installing
first
secure
rear

engine
mounting
member
to

body

2
Refer
to

applicable
section
when

installing
and

adjusting
any
parts

Adjust
clutch

pedal
free
travel
Re

fer

to
Clutch
Pedal
Free
Travel

Section
CL
for
installation
and

adjustment

Adjust
accelerator
control

system

Refer
to

Engine
Control

System

Section
FE
for

adjustment

For

installation
of
air
conditioner

compressor
and
belt

adjustment

Refer
to
Idler

Pulley
and
Com

pressor
Drive
Belt

for

adjustment

of
belt
tension

3
When

installing
exhaust
front

tube
on
exhaust
manifold
be
sure
to

use
new

gasket

4

When

installing
hood

following

engine
installation
be
sure
that

it
is

properly
centered
and
that
hood

lock

operates
securely
Refer
to
Hood

See

tion
BF

for

adjustment
Engine
Removal
Installation

ENGINE
MOUNTING

INSULATOR

FRONT
INSULATOR

Removal

Disconnect

battery
ground
cable

2

Suspend
engine
with
wire

or

chain

3

Remove
front

engine
mounting

insulator

lower
and

upper
nuts
on

both
sides

4
Make

sure
that
wire

or
chain
used

to

suspend
engine
is

positioned

prqper

ly
so
that
no
load
is

applied
to

insulators
and
remove
nuts

complete

ly

5

Lift

up
engine
and

separate
in

sulators

from

engine
mounting
rack

ets

Inspection

If
there
is

damage
deterioration
or

separation
of
bounded
surface
re

place

Installation

Install
front
insulators
in

reverse

sequence
of
removal

noting
the
fol

lowing

1
Do
not
confuse

right
and

left

insulators
R

right
side
or

L

left
side
identification
mark
is

stamp

ed
on
each
insulator

2
Install
front
insulator
so
that

ER
5
position
pin
is

projected
upward

3

Tighten
the

bolts
and

nut
correct

ly
and

securely
See

Fig
ER
I

REAR

INSULATOR

Removal

l

Support
transmission

weight
with

ajack

2
Remove

nuts

securing
rear

engine

mounting
insulator
to

mounting
mem

ber

3
Remove

bolts

connecting
rear
en

gine
mounting
insulator
to
transmis

sion

reaf
extension

housing

4

Jack

up
the

transmission
a
little

and

remove
insulator

Inspection

If
there
is

damage
deterioration
or

separation
of

mating
surface

replace

Installation

Install
rear

engine
mounting
mem

ber
and

insulator
in

reverse
order

of

removal

noting
the

following

I

Install
insulator
in

place
so

that

direction
of
mounted

insulator
is

same

as
that
in

Fig
ER

2

Tighten
nuts
and

bolts

correctly

and

securely
As
for

tightening
torque

see

Fig
ER
l

Engine
Removal
Installation

SERVICE
DATA
AND
SPECIFICATIONS

TIGHTENING

TORQUE

Front

engine
mounting
bracket
to

engine

Front
insulator
to

engine
mounting

bracket

Front
insulator
to

suspension
member

Rear
insulator
to
rear

engine
mounting

member

Rear

engine
mounting
member
to

body

Rear
insulator
to
trailsmission

Clutch

operating

cylinder
to
clutch

housing

Front

tube
to
exhaust
manifold

Propeller
shaft
to

companion
flange

Emaust

mounting
bracket
to
tranSmission
kg
rn
ft
lb

kg
rn
ft
Ib

gem
ft
Ib

g
m
ft
lb

g
m

ft
Ib

g
m
ft
Ib

kg
m
ft
Ib

g
m
ft
lb

kg
m
ft
lb

g
m
ft
Ib

ER
6
1

6
to
2
1

12
to
IS

1
6
to

p
12
0
I

3
2
to
4
3
23
to
31

0
9

to
1
2

6
5
to
8
7

3
2
to

4
3
23
to
31

0
9
to

q
6
5
to
8
7

3
1

to
4
1
22

to
30

1
9

to
2
5

14
to
18

2
4

to
3
3

17
to
24

0
8
to
1
2
5
8

to
8

7

DATSUN
210
Model
8310
Series

SECTIONCL

CLUTCH

CONTENTS

ADJUSTMENT

CLUTCH
PEDAL
HEIGHT

CLUTCH
PEDAL
FREE

TRAVEL

BLEEDING
CLUTCH
SYSTEM

CLUTCH
CONTROL

CLUTCH
PEDAL

CLUTCH
MASTER
CYLINDER

OPERATING
CYLINDER

CLUTCH
LINE

CLUTCH
UNIT

CLUTCH
DISC
AND

COVER
CL
2

CL
2

CL
2

CL
2

CL
3

CL
3

CL
4

CL
5

CL
6

CL
7

CL
7
RELEASE

BEARING

PILOT
BUSHING

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPEctiON
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE
DIAGNOSES
AND

I

ECTIONS

SPECIAL

SERVICE
TOOLS
CL
8

CL
9

CL
10

CL
10

CL10

CL
11

CL
12

CL
14

CLUTCH
PEDAL

HEIGHT

I

Adjust
clutch

pedal
height
H
to

the

specified
range
with

pedal
stopper

adjusting
nut
Then

tighten
lock
nut

CD

2

Adjust
clutch

pedal
free

play
A

to
the

specified
range
at

pedal

pad

with
clutch
master

cylinder
push
rod

Then

tighten
lock
nut

@

Note

a

Pedal
free

play

appeared
due
to

clearance

among
pedal
hole

push

rod
and

piston
should
be

measured

on

top
face
of

pedal
pad

b

Depress
and
release
clutch

pedal

over
its
entire
stroke
to
ensure
that

the
clutch

linkage

operates
smooth

ly
without

squeak
noise

inter

ference
and

binding

I

I

Lock
nut

2

Lock
nut

Cl325

Fig
CL
I

AdjlUting
Clutch

Pedal

Height

Pedal

height
H

143

to
149

mm
5

63
to
5
87
in

Pedal
free

play
An

1

to
5
mm

0
04

to
0

20
in
Clutch

ADJUSTMENT

tfl
Tightening
torque

Lock
nut

CD

0
8

to
1
2

kg
m

5
8
to
8
7

ft
Ib

Lock
nut

@

0
8
to
1

Icll
m

5
8
to
8
7
ft

lbl

CLUTCH
PEDAL

FREE
TRAVEL

Adjust
clutch

pedal
free
travel

whenever
clutch
does
not

disengage

properly
or
whenever
new

clutch

parts
are

i
lslalled

I
Loosen
lock

nut
and

push
nut

djust
length
of

push
rod

by
turning

p
lsh
rod
with

open
end
wrench

until

release

bearing
lightly
touches
clutch

dia

phragm

spring

2

Then
turn

push
rod
back

approxi

mately
I

4
turns
so
that
withdrawal

lever

play
B

clearance
between

withdrawal
lever

push
nut
and
with

drawal
lever

is
within
the

specified

range

V

@

1
B

I

Lock

nut

2
Push
nut

3

Withdrawallcver

CL327

Fig
CL

2

AdjlUting
Clutch

Pedal

Free

Trauel

3

Tighten
lock
nut

against
push

nut

being
careful
not
to
disturb
the

adjustment

4

Depress
and
release
clutch

pedal

several
times

then
recheck

with

drawal

lever

play
B

Readjust
if

necessary

5

Finally
measure

pedal
free
travel

C
at
center
of

pedal
pad

CL
2
Withdrawalle

er
play
nBn

clearance
between
withdrawal

I
er

push
nut
and
withdrawal

le
erl

1
0

to
2
0

mm

0

039
to

0
079
in

Clutch

pedal
free

tr
el
en

at
center
of

pedal
pad

16to33
mm

0
63
to
1
30
in

BLEEDING
CLUTCH

SYSTEM

The

hydraulic
clutch

system
must

be
bled
whenever

clutch
line
has
been

disconnected
or
air
has
entered
it

When

pedal
action
has
a

spongy

feeling
it
is
an
indication
that
air
has

entered
the

system

Bleeding
clutch

system
is

an
essen

tial

part
of

regular
clutch
service

I
Remove

cap
of
reservoir
and

top

up
with
recommended
brake
fluid

2

Thoroughly
clean
mud
and
dust

from
bleeder
screw
of

operating
cyl

inder

so
that
outlet
hole

is
free
from

any

foreign
material
Install
bleeder

hose

vinyl
hose
on
bleeder
screw

Place
the
other
end
of
it
in

a

container

filled
with
brake
fluid

3
Have

a
co
worker

depress
clutch

pedal
two
or

three
times

With
clutch

pedal
depressed
fully
loosen
bleeder

screw

to
bleed
air
out
of
clutch

sys

tem

4
Close
bleeder

screw
quickly
as

clutch

pedal
is
on
down
stroke

5
Allow
clutch

pedal
to
return

slowly
with
bleeder

screw
closed

6

Repeat
steps
3

through
5
until
no

air

bubble
shows
in

the

vinyl
hose

tfl

Tightening
torque

Bleeder
screw

0
7

to
0
9

kg
m

5
1

to
6
5
ft

lbl

7

Depress
and
release

clutch

pedal

several
times
then

check
for

external

hydraulic
leaks
at

connections

Note

a
Brake
fluid

conlaining
air
is

white

and
has

visible
air
bubbles

b

Brake
fluid

containing
no
air

runs

out

of
bleeder
screw
in
a
1lO6d

stream
without
air

bubbles

c

Pay
close
attention
to

clutch
fluid

level

in
reservoir

during
bleeding

operation
Clutch

d

Pour
brake
fluid
into

reServoir

up

to

the

specified
level

CLUTCH
CONTROL

Clutch
ma5ter
cylinder

2

Clutch
disc

assembly

3
Clutch
cover

assembly

4

Release

bearing
and
sleeve

assembly

5

Return

spring

6
Clutch
line

7

Clutch

pedal

8

Operating
cylinder

9
Withdrawal
lever

10
Withdrawal
lever
ball

pin
CAUTION

a
00
not

re
use
brake
fluid

drained

during

bleeding
operation

b

Exercise
care
not
to

splash
brake

fluid
on
exterior
finish
as
it
will

damage
the

paint

e
When

tightening
flare
nut
use
Flal
ll

Nut

Torque
Wrench

GG94310000

CLUTCH
PEDAL

REMOVAL

l

JF

j

1

Clevis

pin

2
Master

cylinder

push
rod

3

Snap
pin

4

E

ring

5

Bushfug

6
autch

pedal

7

Return

spring

j
CL351

Fig
CL
4

Clutch
Pedal

C
L369

Fig
CL

3

Hydraulic
Clutch

Control

System

CL
3
I

Remove

snap
pin
from

end
of

clevis

pin
Separate
master

cylinder

push
rod
from
clutch

pedal

2

Remove
E

ring
from

tip
of
ful

crum

pin
and

take

out
clutch

pedal

and
return

spring

INSPEctiON

Check
clutch

pedal
parts
for
the

following
items

correcting
neces

sary

I
Bent

pedal

2

Weakened
return

spring

3
Worn

or
deformed
clevis

pin
and

fulcrum

bwhings

4

Cracks
at
welded

part

INSTAl1
ATION

To
install
clutch

pedal
reverse
the

order
of
removal
Observe
the
follow

ing

I

Apply

coating
of
recommended

multi

purpose
grease
to

sliding
por

tions
and
return

spring

Lt
of

I

ii

CL352

Fig
CL
5

Lubricating
Point

2
Fit
return

spring
in
hole
in

pedal

bracket
and

securely
fit
E

ring
in
slit

of
fulcrum

pin

3
Insert

clevis

pin
through
clutch

pedal
from
left

to

right
side

4

After

installing
clutch

pedal

check
the

clutch

pedal
height

AdjUst

if

necessary
Refer
to

Adjwtment

CLUTCH

MASTER

CYLINDER

REMOVAL

I
Remove

snap
pin
from

clevis

pin

2
Pull

out
clevis

pin

3
Disconnect
clutch
tube
from
mas

ter

cylinder

4

Remove
master

cylinder
Clutch

CAUTION

When

disconnecting
clutch
tube
use

suitable
flare
nut
wrench

Never
use
an

open
end
wrench
or

adjus1able
wrench

DISASSEMBLY
Note
When

disconnecting
dutch

tube
be
sure
to
receive

draioillll

clutch
fluid
into

a
container
Use
of

rags
is
also

suggested
to

keep

adja

cent

parts
and
area

clean

@

@

1
Reservoir
cap
6

Return

prina
11

Primary
cup
16

StOppel
rins

2
Reservoir
7

Sprina
seat
12
Piston
17
Dust
cover

3
Rescrvou
band

8
Valve

sprina
3

Secondary
cup
18
Lock
nut

4

Cylinder
body
9

Supply
valve
rod

14
Push
rod

5

Supply
yalYe
stopper
10

Supply
valve

15

Stopper

CL345

Fig
CL
6
Clutch
Mcuter

Cylind
r

I
Remove
dwt
cover
and
take
off

stopper
ring
from

body

2
Then
the

push
rod
and

stopper

can
be
taken
out

3

Loosen

supply
valve

stopper
and

take
it

out

4
The

piston
spring
seat
and
reo

turn

spring
can
be
taken
out

Note
Discard

piston
cup
and
dust

cover

CAUTION

Never
detach
reservoir
If

it
is
removed

for

any
reason

discard
it
and
instill

new
one

CL
4
INSPECTION

CAUTION

To
clean
or
wash
all

parts
of
masler

cylinder
clean
brake
fluid
must
be

used
Never
use
mineral
oils
such

as

gasoline
and
kerosene
It
will
ruin
tha

rubber

parts
of
tha

hydraulic
syslBm

I
Check

cylinder
bore
and

piston

for
score
or
rust
and
if
found

replace

2
Check

cylinder
bore

and

piston

for
wear
If
the

clearance
between

cylinder
bore
and

piston
exceeds
the

specified
value

replace
piston
assem

bly
or
master

cylinder
assembly

3

Check
the
condition
of

piston

cup
and
dust
cover

Always

replace

them
after

disassembly

4
Check

all
recesses

openings
and

internal

passages
to

ensure
that

they