Clutch Pedal Assembly: Testing and Inspection

INSPECTION





1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet: 144.9-154.9 mm (5.705-6.098 inch)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on pedal until the beginning of clutch resistance is felt.
Pedal freeplay: 1.0-5.0 mm (0.039-0.197 inch)
Gently push on the pedal until the resistance begins to increase a little.
Push rod play at pedal top: 5.0-15.0 mm (0.197-0.591 inch)





4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY
a. Loosen the lock nut and turn the push rod until the free play and push rod play are correct.
b. Tighten the lock nut.
c. After adjusting the pedal freeplay, check the pedal height.
d. Connect the air duct and install the lower finish panel.





5. CHECK CLUTCH RELEASE POINT
a. Pull the parking brake lever and install wheel stopper.
b. Start the engine and idle the engine.
c. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact.
d. Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position.
Standard distance: 25 mm (0.98 inch) or more
If the distance is not as specified, do the following operation.
^ Check pedal height.
^ Check push rod play and pedal freeplay.
^ Bleed the clutch line.
^ Check the clutch cover and disc.





6. CHECK CLUTCH START SYSTEM
a. Check that the engine does not start when the clutch pedal is released.
b. Check that the engine starts when the clutch pedal is fully depressed.
If necessary, replace the clutch start switch.
7. INSPECT CLUTCH START SWITCH CONTINUITY








Check the continuity between terminals when the switch is ON and OFF.