ZEST BOLT Service Manual

DRIVETRAIN-TA65 Star 17 5.5. MAINTENANCE, ADJUSTMENT AND TESTS 4.5. A PRELIMINARY INSPECTION OF CLUTCH Clutch needs replacement mainly on account of clutch slippage or imperfect engagement and disengagement. This may be due to worn out / damaged clutch parts. It is desirable to carry out the following preliminary checks before removal of the clutch for replacement of the parts. Before carrying out the tests check the clutch cable for damage and also check for proper position of the clutch pedal. INSPECTION OF COMPONENTS i. Check clutch disc hub splines for damage and wear. ii. Check torsion damper mechanism springs for distortion, damage etc. For this purpose, hold drive shaft in vice. Insert clutch disc and slide it as far back as possible. Rotate disc by hand. Rattling noise and excessive play indicates damaged torsional damping mechanism and such disc must be replaced. iii. Check disc facing for wear, cracks, contact pattern, burning marks and oil contamination. Facings with any of the above defects or worn out beyond permissible limits must be replaced. 1. CLUTCH SLIPPAGE TEST Clutch slippage can be confirmed by any of the following two methods: i. Drive the car in 1st or 2nd gear at maximum speed corresponding to that gear. Keeping the accelerator pedal pressed with your right foot, apply brake gradually with your left foot If the engine stalls, it means that clutch does not slip. ii. Drive loaded car in 3rd gear on level ground and let the speed drop down to approximately 15 kmph. Now press the accelerator pedal fully. With slipping clutch, the car speed will not pick up and also clutch burning smell will be noticed. If this does not occur and the car picks up speed, it indicates that clutch does not slip. 2. CLUTCH ENGAGEMENT AND DISENGAGEMENT TEST During the clutch slippage test, when the car is in motion, depress clutch pedal fully without changing the accelerator pedal position. If the engine speed increases immediately, perfect clutch disengagement is indicated. Further, release the clutch pedal suddenly. If the car moves forward with a little jerk, perfect clutch engagement is indicated.