Clutch: Service and Repair

CLUTCH UNIT

Components:

REMOVAL
1. REMOVE MANUAL TRANSMISSION ASSEMBLY
2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY





a) Remove the clutch release fork sub-assembly from the transmission unit.





b) Remove the E-ring, pin and wave washer from the clutch release fork.

3. REMOVE CLUTCH DISC ASSEMBLY

NOTICE: Keep the lining part of the clutch disc assembly, the pressure plate and surface of the flywheel sub assembly away from oil and foreign matter.

4. REMOVE CLUTCH COVER ASSEMBLY
5. REMOVE CLUTCH RELEASE BEARING SHAFT SNAP RING





a) Using a snap ring expander, remove the clutch release bearing shaft snap ring.





b) Remove the clutch release bearing hub, release bearing wave washer and release bearing plate washer.

6. REMOVE CLUTCH RELEASE HUB SNAP RING





a) Using a snap ring expander, remove the clutch release hub snap ring.





b) Remove the clutch release hub ball bearing, thrust cone spring plate washer and thrust cone spring.

7. REMOVE RELEASE FORK SUPPORT





a) Remove the 2 bolts and release fork support from the transmission unit.
b) Remove the release fork support spring from the release fork support.

INSPECTION
1. INSPECT CLUTCH DISC ASSEMBLY





a) Using vernier calipers, measure the rivet head depth.
Minimum rivet depth: 1.3 mm (0.0512 inch)
If the result is less than the minimum, replace the clutch disc assembly.





b) Install the clutch disc assembly to the transmission unit.

NOTICE: Take care not to insert the clutch disc assembly in the wrong direction.

c) Using a dial indicator, check the clutch disc assembly runout.
Maximum runout: 0.8 mm (0.031 inch)
If the runout exceeds the maximum, replace the clutch disc assembly

2. INSPECT FLYWHEEL SUB-ASSEMBLY





a) Using a dial indicator, inspect the flywheel sub assembly runout.
Maximum runout: 0.1 mm (0.004 inch)
If the runout exceeds the maximum, replace the flywheel sub-assembly.

INSTALLATION
1. INSTALL RELEASE FORK SUPPORT





a) Install the release fork support spring to the release fork support.
b) Install the release fork support to the manual transmission unit assembly with the 2 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)

2. INSTALL CLUTCH RELEASE HUB BALL BEARING





a) Install the thrust cone spring, thrust cone spring plate washer and clutch release hub ball bearing to the clutch release hub as shown in the illustration.
b) Using a snap ring expander, install the snap ring.

3. INSTALL CLUTCH RELEASE BEARING HUB





a) Fill the groove inside the release bearing hub with grease.
b) Apply grease to the contact surface between the release hub bearing and the clutch cover.

NOTICE:
^ Be sure to apply an even and thin layer of grease.
^ Excessive grease or a lump of grease on the contact surface between the release hub bearing and the clutch cover can splatter and result in trouble.





c) Using SST, secure the clutch release hub ball bearing.
SST 09950-60020 (09951-00810, 09726-05021)
d) Install the clutch cover assembly, release bearing plate washer and release bearing wave washer.





e) Using a snap ring expander, install the snap ring.

4. INSTALL CLUTCH COVER ASSEMBLY
a) Apply clutch spline grease to the input shaft spline.
Sealant: Part No.08887-01706, CLUTCH SPLINE GREASE or equivalent
b) Install the clutch cover assembly to the input shaft.

5. INSTALL CLUTCH DISC ASSEMBLY





a) Install the clutch disc assembly to the transmission unit.

NOTICE: Take care not to insert the clutch disc assembly in the wrong direction.

6. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY





a) Install the pin and wave washer to the clutch release fork with a new E-ring.





b) Apply release hub grease to the contact surface between, the release fork and release bearing hub, the contact surface between the release fork and push rod, and release fork pivot points as shown in the illustration.
Sealant: Part No.08887-01806, RELEASE HUB GREASE or equivalent
c) Install the clutch release fork sub-assembly to the release fork support.

NOTICE:
^ Do not use excess force to install the clutch release fork sub-assembly.
^ After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.

7. INSTALL MANUAL TRANSMISSION ASSEMBLY