Clutch - ZX 10 kawasaki Motorcycles

Internal leaks in a hydraulic clutch system can be caused by several factors, including:

Worn or damaged seals: If the seals in the clutch system are worn or damaged, fluid can leak past them and cause the clutch to malfunction.

Damaged clutch master cylinder: If the master cylinder is damaged, it may allow fluid to escape, causing the clutch to lose pressure and function poorly.

Air in the system: If air has entered the hydraulic clutch system, it can cause leaks and reduce the effectiveness of the clutch.

Improper installation: If the clutch components were not installed properly, this can lead to internal leaks and reduce the clutch's performance.

Clutch hose damage: If the clutch hose is damaged, this can also cause fluid to leak and reduce the clutch's performance.

If you have recently replaced the clutch components and are still experiencing leaks, I recommend checking all components for damage or proper installation. If necessary, consider taking the vehicle to a mechanic for further inspection and repair.

The related help links to troubleshoot the problem is as follows:---
Click the link below:---
Grinding noise when Clutch pedal is Pushed? http://howtobyme.blogspot.in/2012/05/2001-toyota-celica-grinding-noise-when.html Toyota Celica Noisy Clutch? http://howtobyme.blogspot.in/2012/05/toyota-celica-noisy-clutch.html

--------
No Clutch Pedal No pressure http://whatisbyme.blogspot.in/2012/07/no-clutch-pedal-no-pressure.html 2006 Cadillac cts-v Clutch Getting stuck? http://schematicsdiagram.blogspot.in/2012/04/2006-caddiliac-cts-v-clutch-getting.html

------------
Clutch squealing sound? http://schematicsdiagram.blogspot.in/2012/04/clutch-squealing-sound.html 1995 Jeep Wrangler: Clutch Failed? http://whatisbyme.blogspot.in/2012/06/1995-jeep-wrangler-clutch-failed.html

---------
Clutch squeaking under hood? http://repairhelpcenter.blogspot.com/2012/01/clutch-squeaking-under-hood.html Clutch pedal drags and grabs while changing gears? http://schematicsdiagram.blogspot.in/2012/03/clutch-pedal-drags-and-grabs-while.html Clutch slipping problem? http://howtobyme.blogspot.in/2012/03/clutch-slipping-problem.html

--------
These wil help.
Thanks.

Go with the related help links,to replace the clutch assembly:----Click the link below:---

2004 Peugoet: Clutch not going in gears?
http://whoisbyme.blogspot.in/2012/05/peugeot-307-clutch-will-no-go-in-gears.html
----------
Manual Transmission Clutch System Failures?

http://repairhelpcenter.blogspot.com/2011/11/manual-transmission-clutch-system.html

------------
Car makes noise when clutch is pressed gently? http://schematicsdiagram.blogspot.com/2011/12/car-makes-noise-when-clutch-is-pressed.html

------
How does Clutch works in car?

http://vwrepairhelp.blogspot.com/2011/11/how-does-clutch-works-in-car.html

Clutch pedal hard? http://schematicsdiagram.blogspot.in/2012/02/clutch-pedal-hard.html

---------
2001 Toyota Celica: Grinding noise when Clutch pedal is Pushed? http://howtobyme.blogspot.in/2012/05/2001-toyota-celica-grinding-noise-when.html Toyota Celica Noisy Clutch? http://howtobyme.blogspot.in/2012/05/toyota-celica-noisy-clutch.html

---------
No Clutch Pedal No pressure http://whatisbyme.blogspot.in/2012/07/no-clutch-pedal-no-pressure.html 2006 Cadillac cts-v Clutch Getting stuck? http://schematicsdiagram.blogspot.in/2012/04/2006-caddiliac-cts-v-clutch-getting.html

---------

Here's how I'd try to fix the clutch:
1.) Try to adjust the cable at the handlebar; usually there's a little bid of clutch lever travel (like 1/4"-1/2") before the clutch disengages. For right now, adjust the clutch so that there isn't any play and the adjustment all the way out. If the clutch disengages the transmission, then you know you have to fiddle with the cable to get it adjusted properly.
2.) The clutch plates could be sticking: here you'd have to take the clutch cover off and get to the clutch. Remove the clutch (usually an impact is ideal for removing the clutch holding nut. Take the clutch apart (steels and clutches), make sure they aren't sticking together. Then dip the clutches in oil, then reassemble.
3.) Sometimes the clutch basket (holds all of the clutches and steels in a "basket") gets grooves in it. These grooves prevent the clutch from disengaging. Sometimes you can file the clutch basket fingers down to remove the grooves. Alternatively, if the clutch basket fingers are really worn, you may have to replace the clutch basket.
Typically, when your in the clutch side of the engine case, I'd examine 2 and 3 (above) at the same time.

here's what you can do to fix your clutch.

1. if your clutch still uses clutch cable (there is a cable between the transmision and the clutch pedal), the you can adjust the clutch release by tightening/loosen the clutch pedal. adjustments can be done on the transmission side of the clutch cable.
2. hydrovac clutch with self correcting feature. just pull your clutch pedal for a few seconds and check if the clutch release changes.
3. hydrovac clutch without self correcting. between the clutch pedal and the clutch master, you can see a piece of metal rod that connects the 2. this metal is called push rod. there are screws/nuts at the clutch pedal to adjust this push rod. just adjust this screw to your prefered clutch release.

SECTION 308-00: Manual Transmission/Transaxle and Clutch - General Information 1998 Contour/Mystique Workshop Manual DESCRIPTION AND OPERATION Manual Transaxle and Clutch Manual Transaxle and Clutch - General Information This section covers general procedures for diagnosis and testing the clutch system. For additional information, refer to Section 308-01 . For specified clutch system service procedures. For additional information, refer to Section 308-02 . For a complete description of the manual transaxle. For additional information, refer to Section 308-03 .
The clutch system includes:

• Flywheel.
• Clutch disc.
• Clutch pressure plate.
• Clutch master cylinder.
• Clutch slave cylinder.
• Clutch release fork.
• Clutch release hub and bearing.

The clutch master cylinder transmits fluid pressure to the slave cylinder, which in turn moves the clutch release fork and the clutch release hub and bearing.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master cylinder
The clutch is a single plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The clutch disc has a hub which is splined to the input shaft. The clutch disc has friction material where it contacts the flywheel and the clutch pressure plate. Torsion springs on the clutch disc help absorb the engine torque pulses. The clutch pressure plate applies pressure to the clutch disc, holding it tightly against the surface of the flywheel.
In the engaged position, the diaphragm spring holds the clutch pressure plate against the clutch disc, so that engine torque is transmitted to the input shaft. When the clutch pedal is depressed, the clutch release hub and bearing pushes the diaphragm spring center toward the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted to the clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transaxle and enabling the gears to be changed.
-----------------------------------------------------------------------------------------------------
Inspection and Verification - MTX-75
The following checks should be carried out before repairing or replacing the transaxle:
Poor gear shifting

1. Check the operation of the clutch: Lay a block of wood approx. 25 mm thick under the clutch pedal and depress the clutch pedal as far as the stop. If 1st or 2nd gear can be selected with no problem with the engine running and the parking brake applied, the clutch is OK. If the gear cannot be selected, repair the clutch.

1. Check the selector mechanism:
   • The free play in the gearshift lever must be no more than 15 mm.
     • If the gearshift lever free play is too great, check the gearshift cables and replace them if necessary.
   • If the gearshift lever free play is OK, adjust the gearshift linkage. For additional information, refer to Section 308-06 .

1. Check the transaxle fluid level and top up with Automatic Transmission Fluid ESD-M2C186-A if necessary.

--------------------------------------------------------------------------------------------------------------------------------------

REMOVAL:

1. Lift clutch pedal to uppermost position to disengage clutch and brake pedal pivot shaft.
2. Push clutch and brake pedal pivot shaft forward and unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward.
3. Raise and support vehicle.
4. Remove clutch release lever dust shield.
5. Disconnect clutch release lever cable from clutch release shaft.
6. Remove retaining clip, then clutch release lever cable from flywheel housing.
7. Remove starter motor from flywheel housing, then engine rear plate to front lower flywheel housing bolts.
8. Remove transmission.
9. Remove flywheel housing back just far enough to clear clutch pressure plate, then remove housing.
10. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring disengages from pivot.
11. Remove clutch release hub and bearing from clutch release shaft.
12. Loosen six clutch pressure plate bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate. If same clutch pressure plate is to be installed, mark plate and flywheel so pressure plate can be installed in its original position.
13. Remove clutch pressure plate and clutch disc from flywheel.

INSTALLATION:

1. Position clutch disc and pressure plate assembly on flywheel, noting following:
   1. Three flywheel housing to block dowels on flywheel must be properly aligned with clutch pressure plate.
   2. Bent, damaged or missing flywheel housing to block dowels must be replaced.
   3. tart clutch pressure plate bolts but do not tighten.
   4. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
   5. Align clutch disc using suitable alignment tool inserted in pilot bearing.
   6. To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight, then tighten to specifications.
   
   
2. Install transmission to flywheel housing.
3. Install engine rear plate to flywheel front lower housing bolts, then connect clutch release cable to flywheel housing and connect retaining clip.
4. Connect clutch release lever cable to clutch release shaft, then install clutch release lever dust shield.
5. Install starter motor.
6. Lower vehicle, then install clutch release lever cable as follows:
   1. Lift clutch pedal to disengage clutch and brake pedal pivot shaft.
   2. Push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft.
   
   
7. Cycle clutch pedal several times to adjust clutch release lever cable

the mechanic should place or connect the clutch pedal spring to the clutch pedal .connect the push rod to the clutch pedal.then connect the push rod to the clutch master cylinder then refill the clutch master cylinder .by means of pressure tube connect the clutch slave cylinder .then connect the clutch slave cylinder to the push rod .And the push rod connect it to the clutch pork. the clutch pork connect to the spring. then connect the fly wheel , the clutch linning ,the clutch disk ,the release bearing,then the clutch pork to the transmission shaft . then connect the transmission assembly.And you can goon with your date.

you have civic SI type R with the K20A engine and 6sp transmission? correct?

yes the clutch is adjustable.

1. loosen the clutch pedal position switch(lower of the 2 switches) locknut and back off the clutch pedal position switch.
2. loosen the clutch push-rod locknut and turn the push-rod in or out to get the desired height and stroke of the pedal.
3. tighten the push-rod locknut
4. with the clutch pedal released, turn the clutch pedal position switch in until it contacts the clutch pedal.
5. turn the clutch pedal position switch in an additional 3/4 to 1 turn.
6. tighten the clutch pedal position switch locknut.
7. loosen the clutch interlock switch(the upper switch) locknut and then the interlock switch.
   
8. press the clutch pedal to the floor.
9. release the pedal about 1/2 in. from the fully depressed position, and hold it there. adjust the position of the interlock switch so that the engine will start with the clutch pedal in this position.
10. tighten the interlock switch locknut.

clutch pedal stroke should be: 5.1 - 5.5 in
clutch pedal height should be: 7.76 in

if adjusting the clutch doesn't help with the transmission feeling notchy, may be the syncros.