Clutch Disc: Service and Repair

REMOVAL
1. Drain the clutch fluid and transaxle gear oil.
2. Remove the transaxle assembly.
3. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling.






4. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.


NOTE: DO NOT clean the clutch disc or release bearing with cleaning solvent.

5. Remove the return clip and clutch release bearing.






6. Insert the special tool (09414-24000) in the spring pin and attach the round nut to the end of the tool.






7, While holding the shaft of the special tool (09414-24000) rotate the sleeve with a wrench to force out the spring pin.
8. Remove the clutch release shaft, packings, return spring and release fork.

INSPECTION
CLUTCH COVER ASSEMBLY
Limit: 0.5 mm (0.02 in.)
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil or grease and replace the clutch disc if defective.






2. Measure the rivet sink and replace the clutch disc if it is out of specification.
Limit: 0.3 mm (0.012 in.)
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc. If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.


CLUTCH RELEASE BEARING

Caution: The release bearing is packed with grease. Do not use cleaning solvent or oil.

1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.

CLUTCH RELEASE FORK
1. If there is abnormal wear at the point of contact with the bearing, replace the release fork.






INSTALLATION
. Apply multipurpose grease to the release fork shaft. Pack the portions of the clutch housing which are indicated in the illustration with multipurpose grease.
Grease: MOLYWHITE TA No.2

Caution: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; It can cause clutch slippage and shudder.






2. Align the holes in the release fork with those in the release fork shaft, and drive new spring pins into the holes.

Caution:
(1) Install the spring pins so that the slits cross the centerline of the release fork shaft as.shown.
(2) Do not reuse the spring pins.






3. Apply multipurpose grease into the groove of the release bearing.
Grease: MOLYWHETE TA No.2






4. Apply multipurpose grease to the release bearing contact surfaces of the clutch release fork.
Grease: MOLYWHITE No.2






5. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
6. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Grease: MOLYWHITE TA No.2

Caution: Do not apply more grease than necessary. Too much grease could cause clutch slip or sudder.

7. Using the special tool (09411-11000), install clutch disc to flywheel. When installing the clutch disc, be sure that the surface having the manufacturers stamp is towards the pressure plate side.
8. Install the clutch cover assembly onto the flywheel and install six (6) bolts through the clutch cover into the flywheel.
9. Diagonally tighten the bolts 15 - 22 N.m (150 - 220 kg.cm, 1 - 15 lb.ft).
Tighten the bolts, one or two turns at a time, in succession, to avoid bending the cover flange.
10. Remove the special tool.
11. Install the transaxle. Service and Repair
12. Adjust the clutch pedal free-play.