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14
CLUTCH
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Disconnect pipe connection from slave cylinder.
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Remove split pin and clevis pin, locking master
cylinder push rod fork end with clutch pedal.
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Unscrew and remove two master cylinder
mounting screws. Pull out master cylinder with
push rod.
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Unscrew and remove slave cylinder mounting
screws and pull out slave cylinder.
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Remove split pin and then washer, holding
clutch assistance mechanism with clutch pedal.
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Remove clutch assistance mechanism
carefully.
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Remove two hex nuts holding clutch pedal with
mounting bracket. Take out hex bolt and remove
clutch pedal. Remove collar bush ( of master
cylinder fork mounting ) clutch pedal.
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If clutch pedal bush is to be replaced, remove
it with suitable punch.
9. CLUTCHMASTER CYLINDER
9A. DISMANTLINGOFMASTERCYLINDER
(Fig. 7)
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Pull back dust cover. (14)
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Remove circlip retaining push rod (12)
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Remove push rod with retaining washer (11)
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Remove plunger (10) and valve assembly from
body by lightly tapping the body on wooden
block.
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Using a screw driver, lift the leaf of spring
retainer (8). Remove spring assembly from
plunger.
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Compress spring (6) to free valve stem (7) from
eccentrically positioned hole in the end face of
spring retainer. This will separate spring retainer
from valve stem.
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Remove spring, valve spacer (5) and spring
washer (4) from valve stem.
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Carefully remove valve seal (3) from valve
stem.
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Carefully remove gland seal (9) from plunger.
9B. INSPECTION AND ASSEMBLY OF MASTER
CYLINDER
(Fig. 7)
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Examine bore of body. If it is not scored, ridged
or corroded, do not replace. If there is damage in
the bore, the cylinder assembly should be
replaced. Even otherwise if the clearance between
plunger and the bore exceeds 0.13 mm, the
assembly should be replaced.
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Examine plunger for rust, burrs and ridges,
Replace if necessary.
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Fit new gland seal on plunger such that it fits
squarely in plunger groove.
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Fit new valve seal on valve stemwith the smallest
diameter leading.
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Assemble spring washer on valve stem such that
it bends away from valve shoulder.
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Now assemble valve spacer on valve stem. Hold
the spacer between fingers such that the valve
stem hangs down vertically. Pull the stem
downwards as far as possible. Release the stem.
Observe whether the valve stem has moved
freely upwards. If movement is not free replace
valve spacer.
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Install spring over valve stem behind valve
spacer, followed by spring retainer. Compress
spring and locate valve stem end in key hole slot
of spring retainer.
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Fit spring assembly on plunger assembly and lock
the leaf of spring retainer by pressing it with nose
pliers.
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Lubricate bore of body with brake fluid and dip
plunger valve assembly in it. Insert the assembly
into bore with valve end leading.
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Check condition of dust cover. If necessary
replace.
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If disturbed, adjust push rod length with fork to
specified value.
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Place push rod with retaining washer on plunger
and fit circlip for retaining push rod in the body
groove.
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Fit dust cover on body.