I've searched the archives, and I've seen a lot of clutch adjustment threads, but I couldn't find anything that really addresses my questions. This is for a '95 4dr Kick 1.6 16v.
All of my manuals (93 Kick FSM, 95 Tracker FSM, Hayes, and Chilton's) show two nuts used to adjust pedal free play and a pivot (end) nut for adjusting release lever travel. Ditto Ack's diagram. However, the cable on my Kick has a large rubber stopper thing instead of the two pedal free play nuts. I have a replacement cable from Hawk and it looks just like the one on the Kick. Now, the pictured "three nut" system makes sense. But, what's up with this "one nut, one rubber stopper" system? The end nut could still be used to adjust the release lever travel, but how to adjust the pedal free play? With the single nut on the end of the cable? If so, how do you then adjust the lever travel?
Also, unlike what I see in the diagrams, there is a spring over the cable between the rubber stopper thing and the release lever. It looks like the spring is to hold tension against the end nut. But I can't turn the end nut without the whole cable turning. I'm not out of cable, and the cable isn't corroded. Does this spring sometimes get jammed up against the lever or nut so that it can't turn?
So, to summarize:
Does anyone know how to adjust both pedal and release lever with this funky "one nut, rubber stopper" thing?
Should I just ditch the spring if it's binding and slap on a nylock to back up the end nut?
Thanks.