Inspection Procedure 2

INSPECTION PROCEDURE 2: Clutch Cannot be Disengaged

DIAGNOSIS

STEP 1. Check the excessive clutch pedal play.

Refer to Adjustments.

Q. Does the clutch pedal play meet the standard value?

YES Go to Step 2.

NO Adjust the clutch pedal play. Then go to Step 11.

STEP 2. Check the hydraulic system for leakage, air mix and clogging.

Q. Is there a leakage, air mix or clogging on the hydraulic system?

YES Repair or replace the hydraulic system (Refer to Service and Repair).
Then go to Step 11.

NO [5M/T] : Go to Step 3.

NO [6M/T] : Go to Step 4.

STEP 3. Check the release fork for sticking.

Q. Is the release fork stuck?

YES Repair or replace the release fork Service and Repair).
Then go to Step 11.

NO Go to Step 5.

STEP 4. Check the concentric slave cylinder for deformation.

Q. Is deformation found on concentric slave cylinder?

YES Replace the concentric slave cylinder (Refer to Service and Repair).
Then go to Step 11.

NO Go to Step 5.

STEP 5. Check the clutch disc for distortion and excessive oscillation.

Q. Is the clutch disc distorted or oscillating?

YES [5M/T] : Replace the clutch disc Service and Repair).
Then go to Step 11.

YES [6M/T] : Replace the clutch disc and clutch cover assembly (Service and Repair).
Then go to Step 11.

NO Go to Step 6.

STEP 6. Check the clutch disc spline for wear and corrosion.

Q. Is the clutch disc spline worn or corroded?

YES [5M/T] : Replace the clutch disc Service and Repair).
Then go to Step 11.

YES [6M/T] : Replace the clutch disc and clutch cover assembly (Service and Repair).
Then go to Step 11.

NO Go to Step 7.

STEP 7. Check the clutch disc facing for peeling.

Q. Is clutch disc facing peeling?

YES [5M/T] : Replace the clutch disc Service and Repair).
Then go to Step 11.

YES [6M/T] : Replace the clutch disc and clutch cover assembly (Service and Repair).
Then go to Step 11.

NO Go to Step 8.

STEP 8. Check the clutch cover assembly for wear.

Q. Is the clutch cover assembly worn?

YES [5M/T] : Replace the clutch cover assembly Service and Repair).
Then go to Step 11.

YES [6M/T] : Replace the clutch disc and clutch cover assembly (Service and Repair).
Then go to Step 11.

NO Go to Step 9.

STEP 9. Check the pressure plate and the flywheel for damage.

Q. Is the pressure plate or the flywheel damaged?

YES [5M/T] : Replace the clutch cover assembly Service and Repair) or the flywheel Removal and Installation). Then go to Step 11.

YES [6M/T] : Replace the clutch disc and clutch cover assembly (Service and Repair) or the flywheel Removal and Installation).
Then go to Step 11.

NO [5M/T] : Go to Step 10.

NO [6M/T] : Go to Step 11.

STEP 10. Check the clutch release bearing for wear.

Q. Is the clutch release bearing worn?

YES Replace the clutch release bearing. Then go to Step 11.

NO Go to Step 11.

STEP 11. Check again for the symptom.

Q. Is the symptom reproduced?

YES Return to Step 1.

NO The procedure is complete.