Inspection
CLUTCH DRUM AND INPUT SHAFT ASSEMBLYINSPECTION
1. INSPECT 1 WAY NO. 4 CLUTCH ASSEMBLY
a. Hold the coast clutch hub and turn the 1 way clutch assembly.
b. Check that the 1 way clutch assembly turns freely clockwise and locks counterclockwise.
If there is a problem with the 1 way clutch, replace it.
2. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
a. Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 20.02 mm (0.788 inch)
If the free length is shorter than the standard free length, replace the clutch return spring subassembly.
3. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
a. Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 21.03 mm (0.828 inch)
If the free length is shorter than the standard free length, replace the clutch return spring subassembly.
4. INSPECT DIRECT CLUTCH DISC
a. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt. If necessary, replace them.
NOTICE:
^ If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.
5. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
a. Inspect the pack clearance of the direct clutch.
1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at the both ends across a diameter while blowing air to the oil hole as shown in the illustration, and calculate the average.
HINT:
Flange moving distance A = 0.24 to 1.12 mm (0.0094 to 0.0441 inch)
Pack clearance = Flange moving distance A - 0.03 mm (0.0012 inch)
Pack Clearance: 0.5 to 0.8 mm (0.020 to 0.031 inch)
NOTICE: Install a selective flange (t = 3.4 mm (0.134 inch)) when measuring the moving distance. (shaded area in the illustration.)
2. If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.
HINT: There are 9 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.
Flange Thickness:
6. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
a. Inspect the pack clearance of the reverse clutch hub sub-assembly.
1. Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse clutch flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf-cm 57 psi) from the oil hole as shown in the illustration, and calculate the average.
HINT:
Piston stroke A = 1.90 to 3.00 mm (0.0748 to 0.1181 inch)
Flange moving distance B = 1.38 to 1.86 mm (0.0543 to 0.0732 inch)
Pack clearance = Piston stroke A - Flange moving distance B - 0.03 (0.0012 inch)
Pack Clearance: 0.5 to 0.8 mm (0.020 to 0.031 inch)
NOTICE: Install a selective flange (t = 2.8 mm (0.110 inch)) when measuring the moving distance. (Shaded area in the illustration)
2. If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.
HINT: There are 12 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.
Flange Thickness:
7. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
a. Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 26.29 mm (1.035 inch)
If the free length is shorter than the standard free length, replace the clutch return spring subassembly.
8. INSPECT COAST CLUTCH DISC
a. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt. If necessary, replace them.
NOTICE:
^ If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.
9. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
a. Inspect the pack clearance of the forward clutch.
1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at the both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.
HINT:
Flange moving distance A = 0.14 to 0.17 mm (0.0055 to 0.0067 inch)
Pack clearance = Flange moving distance A - 0.01 mm (0.00039 inch)
Pack Clearance: 0.56 to 0.86 mm (0.0220 to 0.0339 inch)
NOTICE: Install a selective flange (t = 3.5 mm (0.138 inch)) when measuring the moving distance. (shaded area in the illustration.)
2. If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.
HINT: There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.
Flange Thickness:
10. INSPECT FORWARD CLUTCH HUB CLUTCH DISC
a. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt. If necessary, replace them.
NOTICE:
^ If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.
11. INSPECT PACK CLEARANCE OF COAST CLUTCH
a. Inspect the pack clearance of the coast clutch.
1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at the both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.
HINT:
Flange moving distance A = 0.02 to 1.01 mm (0.0008 to 0.0398 inch)
Pack clearance = Flange moving distance A - 0.01 mm (0.00039 inch)
Pack Clearance: 0.4 to 0.7 mm (0.0157 to 0.0276 inch)
NOTICE: Install a selective flange (t = 3.5 mm (0.138 inch)) when measuring the moving distance. (shaded area in the illustration.)
2. If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.
HINT: There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.
Flange Thickness:
12. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY
a. Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
Standard inside diameter: 23.037 to 23.062 mm (0.907 to 0.908 inch)
If the inside diameter is greater than the standard inside diameter, replace the forward clutch hub.
13. INSPECT REAR CLUTCH DISC
a. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt. If necessary, replace them.
NOTICE:
^ If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.
14. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY
a. Using a dial indicator, measure the inside diameter of the reverse clutch hub bushing.
Standard inside diameter: 33.312 to 33.337 mm (1.3115 to 1.3125 inch)
If the inside diameter is greater than the standard inside diameter, replace the reverse clutch hub.