Clutch Pedal Assembly: Service and Repair

Clutch Pedal

REMOVAL
1. Remove the steering column.
2. Disconnect the connector from the stop light switch and clutch switch.
3. Remove the snap pin that fastens the lever and bushing rod to the operating rod.
4. Remove the clevis pin that fastens the lever and bushing rod to the operating rod.





5. Remove the accelerator pedal.
6. Remove the air cleaner case and intake duct. (Non-turbo model)
7. Remove the intercooler. (Turbo model)
8. Remove the PHV adjustment nut and lock nut.





9. Remove the cable clamp and disconnect the PHV cable from the PHV.

CAUTION: When disconnecting the PHV cable, carefully protect the boot and inner cable so that they do not get damaged.





10. Remove the nut that fastens the clutch master cylinder.





11. Remove the bolt and nut that fastens the brake pedal and clutch pedal and remove the pedal assembly.

INSTALLATION
1. Install in the reverse order of removal.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)

NOTE:
^ If the cable clamp is damaged, replace it with a new one.
^ Always cover the outer cable end with the boot.
^ Be careful not to twist the accelerator cable.
^ Always use a new clevis pin.

2. Adjust the clutch pedal after installation.
3. Adjust the clutch switch (clutch start).
4. Adjust the heel holder. (Model with heel holder)

DISASSEMBLY
1. Remove the clip, assist spring, rod and bushing.





2. Remove the spring pin and lever.





3. Remove the clutch pedal and bushing.





4. Remove the stopper, clip, O-ring and rod S, and remove the spring S and bushing S.





5. Remove the stopper from the clutch pedal.
6. Remove the clutch pedal pad.

ASSEMBLY
1. Install the stopper, etc., temporarily to the pedal bracket.
2. Clean the clutch pedal and inside the brake pedal bore, apply grease and set the bushing inside the bore.
Grease: Sunlight No. 2 (Part No. 003602010) or equivalent
3. Align the pedal bracket, clutch pedal and brake pedal bore, and install the brake pedal return spring, assist rod, spring and bushing.

NOTE: Clean the inside of the bushings and apply grease before installing the spacer.

4. Install the heel holder cable to the clutch pedal.

INSPECTION
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lb) to check that the pedal deflection is within the service limit.

NOTE: If excessive deflection is found, replace the bushing with new one.

Deflection of clutch pedal.
Service limit: 5.0 mm (0.197 inch) or less








ADJUSTMENT
1. Measure the full stroke amount of the clutch pedal.

NOTE:
^ Measure the leading end of the seat cushion and center of the pedal.
^ Align the seat with the seventh notch position from the position at the very front.

Clutch pedal standard full stroke: A 130 - 135 mm (5.12 - 5.31 inch)





2. If the full stroke is not within the specified value, loosen the clutch stopper nut to adjust.
Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.)
3. Loosen the bushing rod lock nuts.





4. Rotate the bushing rod to adjust.
1. Make sure that the clutch pedal hits the stopper bolt side when returning the clutch pedal.
2. Check that the clutch pedal hits the clutch pedal bracket stopper at full stroke.





5. Rotate the bushing rod in the shorter direction to create clearance in the stopper bolt or the clutch switch side.





6. Rotate the bushing rod in the shorter direction until the clutch pedal hits the stopper bolt.
7. Rotate the bushing rod further in the longer direction 270° (in the direction of the arrow in the drawing).





8. Check that the clevis pin moves smoothly by moving it in the left and right directions.
9. Tighten the bushing rod lock nut.
Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft. lbs.)
10. Measure the full stroke amount of the clutch pedal again.
Clutch pedal standard full stroke: A 130 - 135 mm (5.12 - 5.31 inch)
11. Install the clutch switch.