Clutch Pedal Assembly: Service and Repair

Clutch Pedal

REMOVAL
1. Remove the steering column.
2. Disconnect the connectors from stop light and clutch switches.
3. Remove the snap pins which secure lever to push rod and operating rod.
4. Remove the clevis pins which secure lever to push rod and operating rod.





5. Remove the air intake chamber. (Non-turbo model)
6. Remove the intercooler. (Turbo model)
7. Remove the nut which secures clutch master cylinder.





8. Remove the bolts and nuts which secure brake and clutch pedals, and remove the pedal assembly.

INSTALLATION
1. Install in the reverse order of removal.

NOTE:
Always use new clevis pins.

2. Adjust the clutch pedal after installation.
3. Adjust the clutch switch (Starter interlock).

DISASSEMBLY
1. Remove the clips, assist spring, rod and bushing.





2. Remove the spring pin and lever.





3. Remove the clutch pedal and bushings.





4. Remove the stopper, clip, O-ring, rod S, and then remove the spring S and bushing S.





5. Remove the stoppers from clutch pedal.
6. Remove the clutch pedal pad. (Non-turbo model)

ASSEMBLY
1. Attach the stopper, etc. to pedal bracket temporarily.
2. Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores.
Grease:
SUNLIGHT 2 (Part No. 003602010) or equivalent
3. Align bores of pedal bracket, clutch pedal and brake pedal, attach the brake pedal return spring, assist rods, spring, and bushing.

NOTE:
Clean up inside of bushings and apply grease before installing the spacer.

INSPECTION
Move the clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbs.) to ensure pedal play is in specified range.

CAUTION:
If excessive movement is noted, replace the bushings with new ones.





ADJUSTMENT
1. Turn the lock nuts until clutch pedal full stroke length is within specifications.

CAUTION:
Do not attempt to turn the clutch switch to adjust clutch pedal full stroke length.

NOTE:
If lock nuts cannot adjust the clutch pedal full stroke length to specifications, turn the master cylinder push rod to adjust it.





2. If the full stroke is out of specifications, loosen the clutch stopper nut (model without cruise control) or clutch switch lock nut (model with cruise control) to adjust.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft. lbs.)
3. Loosen the push rod lock nut.





4. Turn the push rod to adjust.
(1) Make sure that the clutch pedal contacts the stopper bolt side (model without cruise control) or the clutch switch side (model with cruise control) when releasing the clutch pedal.
(2) Make sure that the clutch pedal contacts clutch pedal bracket stopper, when fully depressing the clutch pedal.





5. Turn the push rod to shorten until the clearance is made at the stopper bolt side (model without cruise control) or the clutch switch side (model with cruise control).

^ Model without cruise control





^ Model with cruise control

Model With Cruise Control:

6. Turn the push rod to lengthen until the clutch pedal contacts the stopper bolt (model without cruise control) or clutch switch (model with cruise control).
7. Turn the push rod further 270° to shorten (in the arrow direction as shown in the figure).





8. Move the clevis pin to the right and left to make sure it moves smoothly.
9. Tighten the push rod lock nut.





10. Depress and release the clutch pedal two to three times to ensure that clutch pedal and release fork operates smoothly. If the clutch pedal and release fork do not operate smoothly, bleed air from the clutch hydraulic system.
11. Measure the clutch pedal full stroke length again to ensure that it is within specifications. If it is not, repeat adjustment procedures again from the beginning.
Clutch pedal full stroke:
130 - 135 mm (5.12 - 5.31 inch)
12. Push the release lever until operating cylinder push rod retracts. Ensure that clutch fluid level in reservoir tank increases. If the clutch fluid level increases, the hydraulic clutch is properly adjusted; if fluid level does not increase or push rod does not retract, replace the master cylinder with a new one.





13. Push the release lever until operating cylinder push rod retracts. Check that the clutch fluid level in reservoir tank increases.





14. If the clutch fluid level increases, hydraulic clutch play is correct.
15. If the clutch fluid level does not increase or push rod does not retract, clutch pedal must be readjusted.
16. Check the fluid level on the outside of the reservoir tank. If the level is below "MIN", add clutch fluid to bring it up to "MAX".