Intermediate Technician's Course CLUTCH

2. CHASSIS BASIC OVERVIEW VEHICLE STRUCTURE Rear body Cabin Lamp Axle WHEEL & TIRE

COIL SPRING TYPE CLUTCH 1)OUTLINE AND STRUCTURE RELEASE LEVER CLUTCH DISK CLUTCH COVER PRESSURE PLATE RELEASE BEARING LEVER PLATE CLUTCH SPRING COIL SPRING TYPE CLUTCH

DIAPHRAGM SPRING TYPE CLUTCH FLYWHEEL CLUTCH COVER DIAPHRAGM SPRING RELEASE BEARING BEARING HUB CLUTCH DISK PRESSURE PLATE RELEASE FORK DIAPHRAGM SPRING TYPE CLUTCH

CLUTCH DISK & FACING (LINING) CLUTCH FACING CLUTCH PLATE DAMPER SPRING CUSHION PLATE FRICTION SPRING DAMPER COVER SPLINE HUB FRICTION PLATE CLUTCH DISK & FACING (LINING)

1)SERVICE POINTS : Clutch (1)THE CLUTCH DISK WEAR LIMIT EXPOSED THREADED SECTION

(2)MATCH MARKS ON THE PRESSURE PLATE & CLUTCH COVER MATCH MARKS

(3)COMFIRMATION OF CLUTCH DISK WARP

(4) MEASUREMENT OF CLUTCH SPRING 1 FREE LENGTH

(4)MEASUREMENT OF CLUTCH SPRING 2 SQUARENESS

COMPRESSION SPRING SETTING LENGTH (4)MEASUREMENT OF CLUTCH SPRING 3 COMPRESSION SPRING SETTING LENGTH COMPRESSION SPRING SETTING LOAD

(5)REMOVE THE SERVICE BOLTS

(6)ADJUSTMENT OF THE RELEASE LEVER HEIGHT

RELEASE LEVER RELEASE LEVER HIGHT GAUGE ADJUST BOLT

QUESTIONS TO CONSIDER: (1) What will happen if the service bolts are not removed after the clutch assy has been installed? SERVICE BOLTS

The clutch will remain disengaged and the vehicle will not be able to start. SOLUTIONS: SERVICE BOLTS

QUESTIONS TO CONSIDER: (2) What will happen if the release lever height is not the stipulated value? Lever height is not same.

SOLUTIONS: Clutch judder, rough start, gear noise. ( when changing gears. ) SOLUTIONS: Lever height is not same.

QUESTIONS TO CONSIDER: (3) What will happen if the clutch disk is installed backward?

SOLUTIONS: The clutch boss will gear with the flywheel and the clutch will not be disengaged, so the engine will not start.

QUESTIONS TO CONSIDER: (4) What might cause a clutch disk damper spring to break? DAMPER SPRING

SOLUTIONS: Repeated rapid engage.

QUESTIONS TO CONSIDER: (5)If the clutch disk wears prematurely, what do you think might cause this? SOLUTIONS: Faulty adjustment, faulty driving, riding the clutch.

QUESTIONS TO CONSIDER: (6) What condition dose clutch slipping refer to? SOLUTIONS: Vehicle can not start when carrying cargo.

QUESTIONS TO CONSIDER: (7) What will happen if the clutch disk is significantly warped?

SOLUTIONS: Clutch judder, gear noise. ( when changing gears. )

QUESTIONS TO CONSIDER: (8) What will cause the pressure spring free length to shorter and what symptoms will that produce? FREE LENGTH

SOLUTIONS: Spring distortion due to heat produced by clutch disk slipping; clutch slipping.

QUESTIONS TO CONSIDER: (9) What will cause the pressure plate installation load to drop and what symptoms will that produce? INSTALLATION LOAD

SOLUTIONS: Spring distortion,excessive pressure plate skimming, clutch slipping.