1. Intermediate Technician's Course
CLUTCH

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

3. 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

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

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

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

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

8. (3)COMFIRMATION OF CLUTCH DISK WARP

9. (4) MEASUREMENT OF CLUTCH SPRING 1
FREE LENGTH

10. (4)MEASUREMENT OF CLUTCH SPRING 2
SQUARENESS

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

12. (5)REMOVE THE SERVICE BOLTS

13. (6)ADJUSTMENT OF THE RELEASE LEVER HEIGHT

14. RELEASE LEVER
RELEASE LEVER HIGHT GAUGE
ADJUST BOLT

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

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

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

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

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

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

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

22. SOLUTIONS:
Repeated rapid engage.

23. 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.

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

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

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

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

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

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

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