ZICA

DRIVETRAIN-TA65 Star

.6. E CLUTCH SWITCH ADJUSTMENT

PROCEDURE:

EMS switch gap as shown in the below image

should be set such that the switch becomes

'ON' at 64±4 mm of clutch pedal travel from its

initial position.

To ensure clutch pedal height setting properly,

follow below instructions.

After setting clutch pedal in line with brake pedal,

pump the clutch pedal for 10 to 15 times, after that

start engine and run the vehicle for 2 to 3 Kms with

clutch pedal actuations like city cycles traffic

bumper to bumper, check clutch pedal height and

reset if required.

4.6. F. REMOVAL OF CLUTCH FROM THE CAR:

1. Position and Lift the car using two post lift.

2. Disconnect battery and electrical connections of

the starter motor.

3. Loosen mounting bolts and remove starter

motor. Disconnect and remove transaxle along

with clutch housing from engine (for procedure

refer transaxle group)

4. Remove clutch release bearing with sleeve

5. Support clutch pressure plate and clutch disc

with mandrel & remove.

NOTE:

It is recommended to replace a defective disc

having any of the above mentioned defects with

a new genuine clutch disc. We do not

recommend removal and replacing of clutch

facing.

We do not recommend overhauling of the

clutch pressure plate assembly. However,

before re-fitment, the assembly should be

checked for specifications and should conform

to the data of clutch pressure plate assembly

given on page 3.

Use correct clutch discs for the 1.22 NG NA

versions Identification.

Use Disc and Pressure plate of the same make.

Ensure that the clutch facing material is not

contaminated with oil or grease as this shall

result in clutch slipping.

4.6. G. INSTALLATION OF CLUTCH ON THE

CAR:

Carryout the clutch removal steps in appropriate

sequence for its fitment. However, following care

must be taken during installation.

Clean friction face of flywheel and check for

cracks, scoring, burn marks or unevenness. If

necessary, machine flywheel friction face just to

clear the defect.

Lightly apply Dow corning P40 grease on the disc

splines. Install disc and pressure plate assembly.

Press the aligning mandrel through the pressure

plate assembly and clutch disc and centralize

clutch disc on flywheel by locating the mandrel at

the flywheel end.

NOTE:

Do not mix clutch mounting bolts with other

fasteners. Do not use longer or shorter screws.

Longer screws may not tighten the clutch at all.

Shorter screws will not provide enough threads to

achieve desired tightening.



While tightening the clutch mounting screws

check aligning mandrel for continuous free

sliding to ensure concentric installation of clutch

disc which will avoid trouble during the

installation of the transaxle.