SECTION 5

CLUTCH SYSTEM

CONTENTS

5.1 CLUTCH ASSEMBLY ........................................................................................................................................1

5.2 CLUTCH SYSTEM OIL RESERVOIR ................................................................................................................1
5.3 CLUTCH SYSTEM CHECKS .............................................................................................................................2
5.3.1 Clutch Plate Unbalance Check.....................................................................................................................3
5.4 DE-AERATION OF CLUTCH SYSTEM .............................................................................................................3
 CLUTCH SYSTEM

5.1 CLUTCH ASSEMBLY

Clutch System used in NAVIGO vehicles is hydraulic

power activated, single plate spring disc (Ø350 mm)
type.

In order to replace the clutch assembly transmission

should be disassembled.

5.2 CLUTCH SYSTEM OIL RESERVOIR

The clutch oil reservoir is at the front of the vehicle on

the clutch system control valve group which is
located on the right when you open the front flap.
The recommended oil is Mobil Brake Fluid.

The minimum and maximum oil levels are marked on

the reservoir as MIN and MAX respectively. Check oil
level is between these marks. Add oil as required.
To add oil open the reservoir cap and close it after
filling required amount.

Change clutch hydraulic fluid after every 200 000

km or 2 years.

KOTAKE2C07 / Section 5 - 1
CLUTCH SYSTEM

5.3 CLUTCH SYSTEM CHECKS

• Check the flywheel ring gear for wear, breaks or

teeth damage. If it is required to be replaced heat it
up to 210˚C install on the flywheel.
• If flywheel is replaced or grinded check mounting
bolts’ tightening torque (25Nm +/- 5).

• Check oscillation of flywheel due to unbalance by

use of a dial indicator. It should not be more than
0.05mm – 0.07mm.

• Check the spring plate and the spring on the

clutch plate for wear, breaks or looseness. If any
problem observed, replace the complete set.
• Check clutch plate surface for cracks, withered
areas, or greasy areas.
• Check clutch shaft is moving easily on the milled
teeth.
• Check center shaft in the clutch plate is in
horizontal position.

KOTAKE2C07 / Section 5 - 2

NOTE:
If any problem observed in the above checks,
replace complete set (i.e. clutch plate, drive
group and bearing).
Apply Molybdenum disulfide type of grease on
the milled teeth of clutch shaft before assembling
the component. This will reduce the possibility of
occurrence of damage on the teeth.
The centricity of the clutch plate, thrust plate and
flywheel is important during assembly.
Tightening torque for thrust plate – flywheel
mounting bolts should be 21Nm + / - 5.
5.3.1 Clutch Plate Unbalance Check
1. Mount clutch plate on to a center bench.
2. Assemble a dial indicator to the
circumference of the plate.
3. Turn the plate slowly. Check the fluctuations
on the dial indicator.
4. If the fluctuations excess 0.25mm replace the
set.
CLUTCH SYSTEM
5.4 DE-AERATION OF CLUTCH SYSTEM
After disassembly and assembly of clutch and guard
assemblies system should be de-aerated as follows:
NOTE:
To avoid air entrance to the system during the
following steps check oil level in the reservoir
continuously and keep reservoir full. Hydraulic
fluids tend to absorb moisture from the air. For
this reason always refill the system or add fresh
oil, as possible.
2. Determine a hose which will fit to the de-aeration
screw located on the clutch oil control valve group.
3. Fill a glass container with hydraulic brake oil.
4. Fit one end of the hose to the screw and insert
the other end into the fluid in the glass.
Loosen the de-aeration screw and press the clutch
pedal inside the vehicle continuously until air bubbles
in the glass vanishes. When no air bubble go out of
the hose tighten the de-aeration screw while keeping
the clutch pedal pressed.
KOTAKE2C07 / Section 5 - 3
CLUTCH SYSTEM

THIS PAGE IS INTENTIONALLY BLANK

KOTAKE2C07 / Section 5 - 4