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A hard or stiff pedal usually does not develop in the clutch assembly itself.
The hard or stiff pedal almost always comes from the clutch release system.
All systems:
 | The release bearing can bind on the one the bearing retainer or quill.
This also is hard to check by moving the bearing with-out the proper load.
However the bearing will make grooves or marks on the retainer or quill
which are the tell tale signs of trouble. |
| Check that the clutch pedal is not binding. The pedal can binds on it's
bushing if it's not lubricated. Spraying penetrating oil may give you free
movement initially, but should be followed up with regular oil or grease. A
worn or missing bushing will also cause binding. |
| Check all pivot points for lube and wear. Lube or replace as necessary,
this includes the clutch fork. |
Cable system:
| A cable can bind in it sleeve causing a hard pedal. When detached the
cable seems to wrong effortlessly and smoothly. There is no way to properly
test if a clutch cable is binding with-out the loads and curves that a cable
has. Replace the cable if all other pivot points are freely working. |
Hydraulic system:
| You may get a hard or stiff pedal if while installing a new hydraulic
system the line or hoses get kinked. |
| Binding or dragging plunger in the Master or Slave cylinder can also cause
a hard pedal. This is very difficult to diagnose, be careful not to jump to
conclusions! Flush the hydraulic system with clean fluid to try to clear
this problem. |
| Blocked compensating port. Adjust the push rod, refill the system and
bleed. |
Mechanical system:
| Check all linkages. Worn or non lubricated connections could be your
problem. Don't look to find "the one bad piece", a few small
problems can add up to one big one. |
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