Repair Procedures

Removal

1. Drain the brake fluid through the bleeding plug (A).




2. Remove the flexible hose (A) connected to brake reserve tank from the master cylinder.




3. Disconnect the clutch tube (B) from the master cylinder.
4. Disconnect the two ignition lock switch connectors.
5. Remove the clutch pedal mounting nuts(A-2ea) and the bracket mounting nut.




6. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).




7. Remove the screws mounting the master cylinder to the clutch pedal assembly.

Installation

1. Apply the specified grease to the clutch pedal and bushings.

Chassis grease: SAE J310a, NLGI No.1





2. Install the screws or nut mounting the master cylinder to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and washer.

Wheel bearing grease: SAE J310, NLGI No.2


4. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer (B).




5. Install the clutch pedal mounting nuts (A-2ea).

Tightening torque :
17 - 26Nm (1.7 - 2.6kgf.m, 12.3 - 18.8Ib-ft)









6. Adjust the clutch pedal within the standard value, then secure by tightening the lock nut.

Standard value
Free play (A)
6 - 13mm (0.24 - 0.51 in)
Height (B)
182.8mm (7.19 in)





7. Connect the flexible hose of the brake reserve tank to the master cylinder.




8. Connect the clutch tube(B) to the master cylinder.
9. Refill the brake fluid.
10. Bleed the air in the clutch system.(refer to Bleeding in Serve Adjustment Procedure)