Clutch Pedal Assembly: Service and Repair

Clutch Pedal

REMOVAL
1. Remove the steering column.
2. Disconnect the connectors from stop light and clutch switches.
3. Remove the snap pins which secure lever to push rod and operating rod.





4. Remove the clevis pins which secure lever to push rod and operating rod.
5. Remove the accelerator pedal.
6. Remove the air cleaner case and intake duct.





7. Remove the PHV adjusting nut and lock nut.





8. Remove the cable clamp, and disconnect the PHV cable from PHV.

CAUTION: Carefully protect the boot and inner cable from damage when disconnecting the PHV cable.





9. Remove the nut which secures clutch master cylinder.
10. Remove the bolts and nuts which secure brake and clutch pedals, 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.
^ Never fail to cover the outer cable end with boot.
^ Be careful not to kink the accelerator cable.
^ Always use new clevis pins.

2. Adjust the clutch pedal after installation.
3. Adjust the clutch switch (starter interlock).
4. Adjust the hill holder.(with hill holder)

DISASSEMBLY





1. Remove the clips, assist spring, rod and bushing.





2. Remove the spring pin and lever.





3. Remove the clutch pedal and bushings.





4. Remove the stopper, clip, O-ring, rod S. and then remove the spring and bushing S.
5. Remove the stoppers from clutch pedal.
6. Remove the clutch pedal pad.

ASSEMBLY
1. Attach the stopper, etc. to pedal bracket temporarily.
2. Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores.
Grease: SUNLIGHT No.2 (Part No. 003602010 or equivalent
3. Align bores of pedal bracket, clutch pedal and brake pedal, attach the brake pedal return spring, assist rods, spring, and bushing.

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

4. Install the hill holder cable to clutch pedal.

INSPECTION
CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lb) to ensure pedal deflection is in specified range.





NOTE: If excessive deflection is noted, replace the bushings with new ones.

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

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





NOTE:
^ Measure the length between seat cushion front end and center portion of clutch pedal.
^ Slide the seat at seventh notch from first notch.

Specified clutch pedal full stroke: A 130 - 135 mm (5.12 - 5.31 inch)
2. If not as specified, loosen the clutch stopper nut to adjust it.
Tightening torque (Clutch stopper nut): 8 Nm (0.8 kgf-m, 5.8 ft. lbs.)





3. Loosen the push rod lock nut.





4. Turn the push rod to adjust.
1. Ensure that the clutch pedal contacts stopper bolt, when releasing the clutch pedal.
2. Ensure that the clutch pedal contacts clutch pedal bracket stopper, when fully depressing the clutch pedal.
5. Turn the push rod clockwise to shorten until clearance is made at stopper bolt or clutch switch.





^ Without cruise control





^ With cruise control





6. Turn the push rod counter clockwise to lengthen until clutch pedal contacts to stopper bolt.
7. Turn the push rod further 270° counterclockwise to lengthen (arrow direction as shown in the figure).
8. Move the clevis pin in lateral direction to ensure it moves smoothly.
9. Tighten the push rod lock nut.
Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft. lbs.)
10. Measure the full stroke amount of clutch pedal again.
Specified clutch pedal full stroke: A 130 - 135 mm (5.12 - 5.31 inch)
11. Install the clutch start switch.