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Replacement

1. Remove the clutch cable

(1) Loosen the clutch adjusting nut. Separate the clutch cable from the accelerator rocker arm

(2)  Remove the 2 set bolts from the clutch cable on the cowl panel

(3) Separate the clutch cable from the clutch pedal

2. Install the clutch cable assembly in the reverse order of the above procedure.

Notice:

(1) The clutch cable assembly on the cowl panel set bolt torque : 20~25N.m

(2) Check and adjust the pedal according to the above-mentioned requirement in

"Adjustment".

Adjusting Bolt

Stroke

Free 
Stroke

Minimum Distance from the Cowl Panel 

 Adjusting Bolt 

Nut

Install Height

Adjusting Nut

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Section 3 Clutch hydraulic Control Device

Components

Clutch Sub-pump

T

ransmission Assembly

Reserv

oir

Co

wl Baf

fle

Clutch 

And Brak

e Pedal 

Assembly

Clutch Master Cylinder

Clutch Master 

Cylinder

Master Cylinder Brack

et

Clamp 

Clamp 

Connect The 

Pipe 

Assembly

Hose Union 

Reserv

oir Hose 2

Reserv

oir Hose 1

Clog Bolt

Rubber W

asher 

Union Nut

Hydraulic Hose

L Shaped Clip Plate 

  L Shaped Clip Plate

Pivot

95

Replacement

1. Remove the reservoir hose 1 and reservoir hose 2

Notice: Clutch hydraulic control system and hydraulic

brake system share the reservoir. Prevent the brake

fluid from overflowing when removing the reservoir

hose.

2. Disconnect the connection with the pedal

Remove the lock pin, flat washer, pin shaft to separate the clutch hydraulic control master cylinder from

the clutch pedal

3. Remove the connecting pipe

Loose the threaded connector connecting pipe and the clutch master cylinder. Remove the connecting

pipe.

4. Remove the clutch pedal assembly

Remove the nuts, bolts, 2 bushing, sleeve, clutch pedal assembly

5. Remove the hydraulic hose

Loosen the union thread connecting clutch hydraulic hose and pipe. Remove E-shaped clip plate fixing

the both ends of the clutch hydraulic hose

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6. Remove clutch hydraulic control master cylinder

Remove the 2 fixing bolts between the clutch hydraulic control master cylinder and the pedal bracket

7. Install and replace the parts in the reverse order of the above procedure

Notice:

 (1) Be careful not to leak brake fluid onto other objects or paint surface. Clean it immedi-

ately to avoid damage.

 (2) Do not damage the seal rubber when installing and removing the pipe and make sure the

installation is correct

 (3) Clutch pedal set thread torque : 20~25N.m

 (4) Clutch hydraulic control master cylinder set bolt torque : 20~25N.m

 (5) Torque of the union thread connecting the pipe and clutch master cylinder:

12~16N.m

 (6) Torque of the threaded connector connecting the clutch hydraulic hose and pipe:

12~16N.m

 (7) Bleed the air in the clutch hydraulic control system

 (8) Check the clutch hydraulic control system for leakage

 (9) Check the clutch hydraulic control system for reliable working

 (10) Check the brake fluid level. Fill the brake fluid of the same brand if necessary.

 (11) Check the clutch pedal installation height stroke and free stroke

a . The clutch pedal installation height: 180~186 mm

b . The clutch pedal stroke: 134~142mm

c . The clutch pedal free stroke: 10~20 mm