9 CLUTCH 11. INSTALLATION OF CLUTCH ACTUATION MECHANISM ● Install clutch pedal bush if removed earlier, using suitable drift. ● Locate clutch pedal in the mounting bracket properly and insert hex bolt. Note Smear oil on inside surface of clutch pedal bushwhile assembling. ● Fit and tighten two hex nuts with clutch pedal mounting bolt. Ensure free movement of lever after tightening. ● Locate clutch actuation mechanism properly. Push the eye end and fit it on the mounting pin at clutch pedal carefully. Install washer and split pin and bend the split pin. ● Mount slave cylinder on clutch housing. Make sure that push rod end is properly located at clutch fork seat. ● Ensure that bleeding screw of slave cylinder is at top. Tighten slave cylinder mounting nuts. ● Install master cylinder on fire wall and tighten its mounting screws. ● Install push rod fork and clutch pedal. Insert clevis pin. Install plain washer and lock clevis pin with split pin. ● Connect pipe connection to slave cylinder. ● Connect pipe connection to master cylinder properly. 12. BLEEDING THE 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. 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 CLEARANCE BETWEEN PLUNGER AND PUSH ROD OF MASTER CYLINDER.THIS CANNOT BE ADJUSTED. IT IS BUILT IN DESIGNFEATURE. ● Ensure before assembling the clutchmaster cylinder on the firewall that the dimension 128 mm. (Push rod fork hole centre tomaster cylinder flange face) is properly adjusted. (Fig.6) ● Assemble the master cylinder on firewall. ● Assembletheclutchpedalandthemastercylinderpush rodforkwithpin, collarbush,washer andsplitpin. Note Smear oilwhileassembling thepivot pinof 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 clutchpedal travel to160+5mmby adjusting clutchpedal stopper. ● Screw out the bolt further by one turn. Tighten the locknut. ● Press the clutchpedal 3-4 times andcheck for proper functioning. Fig.9- Bleeding the clutch system
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