SAFARI

14 CLUTCH l Disconnect pipe connection from slave cylinder. l Remove split pin and clevis pin, locking master cylinder push rod fork end with clutch pedal. l Unscrew and remove two master cylinder mounting screws. Pull out master cylinder with push rod. l Unscrew and remove slave cylinder mounting screws and pull out slave cylinder. l Remove split pin and then washer, holding clutch assistance mechanism with clutch pedal. l Remove clutch assistance mechanism carefully. l 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. l If clutch pedal bush is to be replaced, remove it with suitable punch. 9. CLUTCHMASTER CYLINDER 9A. DISMANTLINGOFMASTERCYLINDER (Fig. 7) l Pull back dust cover. (14) l Remove circlip retaining push rod (12) l Remove push rod with retaining washer (11) l Remove plunger (10) and valve assembly from body by lightly tapping the body on wooden block. l Using a screw driver, lift the leaf of spring retainer (8). Remove spring assembly from plunger. l 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. l Remove spring, valve spacer (5) and spring washer (4) from valve stem. l Carefully remove valve seal (3) from valve stem. l Carefully remove gland seal (9) from plunger. 9B. INSPECTION AND ASSEMBLY OF MASTER CYLINDER (Fig. 7) l 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. l Examine plunger for rust, burrs and ridges, Replace if necessary. l Fit new gland seal on plunger such that it fits squarely in plunger groove. l Fit new valve seal on valve stemwith the smallest diameter leading. l Assemble spring washer on valve stem such that it bends away from valve shoulder. l Now assemble valve spacer on valve stem. Hold the spacer between fingers such that the valve stem hangs down ver tically. 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. l 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. l Fit spring assembly on plunger assembly and lock the leaf of spring retainer by pressing it with nose pliers. l Lubricate bore of body with brake fluid and dip plunger valve assembly in it. Insert the assembly into bore with valve end leading. l Check condition of dust cover. If necessary replace. l If disturbed, adjust push rod length with fork to specified value. l Place push rod with retaining washer on plunger and fit circlip for retaining push rod in the body groove. l Fit dust cover on body.