SAFARI

CLUTCH

Note

During bleeding process keep a watch on fluid

level in container and top up if the level falls below

the indicated mark.

13. CLUTCH PEDAL LINKAGE ADJUSTMENT

CLUTCH PEDAL FREE PLAY IS DUE TO

CLEARANCEBETWEENPLUNGERANDPUSH

ROD OF MASTER CYLINDER. THIS CANNOT

BE ADJUSTED. IT IS BUILT IN DESIGN

FEATURE.

Ensure before assembling the clutch master

cylinder on the firewall that the dimension 126

mm. (Push rod fork hole centre to master cylinder

flange face) is properly adjusted. (Fig.7)

Assemble the master cylinder on firewall.

Assemble the clutch pedal and the master

cylinder push rod fork with pin, collar bush,

washer and split pin.

Note

Smear oil while assembling the pivot pin of clutch

lever.

Screw in pedal stopper bolt completely. Press

pedal fully till the pedal bottoms on the floor. Now

screw out the pedal stopper bolt till it touches

the pedal lever, release pedal. (Fig.5)

Set the clutch pedal travel to 145-150 mm by

adjusting clutch pedal stopper.

Screw out the bolt further by one turn. Tighten

the locknut.

Press the clutch pedal 3-4 times and check for

proper functioning.

12. BLEEDINGTHE CLUTCH SYSTEM

The procedure for bleeding the system is as

follows :

Top up clutch fluid container.

Ensure that fluid level in clutch fluid container is

up to ‘Max’ level and not above it. Add clutch

fluid to maintain level while bleeding.

Remove dust cap from slave cylinder bleed screw

and clean the screw thoroughly. Attach bleeding

tube to bleed screw and place other end of tube

in a clean glass jar containing sufficient clutch

fluid to submerge tube end.

Pump clutch pedal twice or thrice slowly

throughout its stroke and by holding clutch pedal

in depressed condition, loosen bleed screw on

cylinder.

Retighten bleed screw on slave cylinder and

repeat the above operation until air bubbles cease

to appear at the end of tube in glass jar, allowing

only fluid to flow.

After completing bleeding operation, ensure that

bleed screw on slave cylinder is fully tightened.

Replace dust cap on the bleed screw.

Fig.9- Bleeding the clutch system