Clutch Hydraulic System Diagnosis

NOTICE: The clutch master and actuator cylinder assembly is to be serviced as a complete unit. It is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap.





1. Measure fork travel through access hole.
a. Using a caliper, measure travel of fork with clutch pedal in full-up position and then in full-down position.
b. Subtract full-down position from full-up position to determine clutch fork travel.
-OR-
a. Using a piece of round wire rod, mark the full-up and full-down position on the rod.
b. Measure the distance between the two marks to determine the clutch fork travel.
If fork travel is less than 10.80 mm (0.43 inch) travel is insufficient.
2. If fork travel is less than 10.80 mm (0.43 inch), check the following:

IMPORTANT: The first three items require clutch master and actuator cylinder assembly replacement.

- Fluid leaks in hydraulic system.
- Damage to front of dash.
- Air in system.
- Damaged master/slave cylinder.
- Master/slave cylinder improperly installed.





3. Measure pedal travel. Pedal travel should be 117 mm -137 mm (4.6 - 5.4 inch).
If pedal travel is insufficient, check for:
- Carpet or floor mat under pedal.
- Faulty bushing/damaged pedal.
4. If fork travel and pedal travel are ok and clutch hydraulics are functioning properly, check for:
- Bent fork.
- Damaged clutch housing cover assembly (pressure plate).