Clutch Disc: Service and Repair

REMOVAL
1. Remove transmission from engine.
2. Remove clutch cover and disc, as follows:



a. Place matchmarks on the flywheel and clutch cover.
b. Loosen each set bolt one turn at a time until spring tension is released.
c. Remove the set bolts, and pull off the clutch cover with the clutch disc.

NOTICE: Do not drop the clutch disc.

3. Remove release bearing, fork and boot from transmission, as follows:
a. Remove the clips, and pull off the bearing and hub.



b. Remove the fork and boot.

INSTALLATION
1. Install clutch disc and cover on flywheel, as follows:



a. Insert Special Service Tool (SST) 09301-00110 in the clutch disc, and then set them and the cover in position.
b. Align the matchmarks on the clutch cover and flywheel.



c. Tighten the bolts evenly and gradually while pushing the SST. Make several passes around the cover until it is snug. Torque the bolts on the clutch cover in order shown.
Torque: 19 Nm (14 ft. lbs.).

NOTE: Temporarily tighten the No.1 and No.2 bolts.




2. Check diaphragm spring tip alignment. Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch).
If alignment is not as specified, using SST 09333-00013 or equivalent, adjust the diaphragm spring tip alignment.

3. Apply molybdenum disulfide lithium base grease (NLGI NO.2), as follows:



a. Apply release hub grease to the these parts:
- Release fork and hub contact point
- Release fork and push rod contact point
- Release fork pivot point
b. Apply clutch spline grease to the clutch disc spline.
NOTE: Recommended grease part number 08887-01706 (100 g).

4. Install release bearing, fork and boot to transmission, as follows:
a. Install the bearing assembly to the fork, and then install them to the transmission.
b. Install the boot.

5. Install transmission to engine.