SAFARI

16 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. l 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) l Assemble the master cylinder on firewall. l 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. l 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) l Set the clutch pedal travel to 145-150 mm by adjusting clutch pedal stopper. l Screw out the bolt further by one turn. Tighten the locknut. l 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 : l Top up clutch fluid container. l 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. l 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. l Pump clutch pedal twice or thrice slowly throughout its stroke and by holding clutch pedal in depressed condition, loosen bleed screw on cylinder. l 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. l 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