CLUTCH RELEASE CYLINDER(for 1WW) INSTALLATION

PROCEDURE

  1. INSTALL CLUTCH RELEASE CYLINDER KIT

    1. CL00672

      Coat a new piston with lithium soap base glycol grease as shown in the illustration.

    2. Install the piston and a new spring to the release cylinder body.

      Note:

      Do not damage the inside of the release cylinder body.

      Tip:

      Install the smaller end of the spring to the piston.

    3. Install a new boot to the push rod.

    4. Install the push rod together with the boot to the release cylinder body.

  2. TEMPORARILY INSTALL RELEASE CYLINDER BLEEDER PLUG

    1. C299392

      Install the release cylinder bleeder plug to the release cylinder body.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

    2. Install the bleeder plug cap to the bleeder plug.

  3. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

    1. C299391

      Install the clutch release cylinder assembly with the 2 bolts.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  4. CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

    1. C299390

      Using a union nut wrench, connect the clutch release cylinder to flexible hose tube.

      15 N*m

      155 kgf*cm

      11 ft.*lbf

      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

  5. BLEED CLUTCH LINE

    Click here

  6. INSPECT FLUID LEVEL

    Click here

  7. INSPECT FOR FLUID LEAK

    Tip:

    Check for leaks in the clutch system.

  8. INSTALL NO.1 AIR TUBE ASSEMBLY

    Click here

  9. INSTALL BATTERY CARRIER ASSEMBLY

    Click here

  10. INSTALL BATTERY TRAY

  11. INSTALL BATTERY

  12. INSTALL BATTERY INSULATOR

  13. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  14. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  19. ADD ENGINE COOLANT

    Click here

  20. INSPECT COOLANT LEAK

    Click here

  21. INSTALL NO.1 ENGINE UNDER COVER

    Click here