Clutch Assembly Service

Inspection and Adjustment
CLUTCH DISC
Check the following items, and replace if necessary.
- Clutch disc, for burns, discoloration, oil or grease leakage





- Clutch disc, for wear of facing
Wear limit of facing surface to rivet head: 0.3 mm (0.012 inch)





- Clutch disc, for backlash of spline and runout of facing
Maximum backlash of spline (at outer edge of disc)
1.0 mm (0.039 inch)
Runout of facing limit (at outer edge of disc)
1.0 mm (0.039 inch)
Distance of runout check point (from hub center)
Model 240: 115 mm (4.53 inch)
Model 250: 120 mm (4.72 inch)

CLUTCH COVER AND FLYWHEEL





- Check clutch cover, installed on vehicle, for uneven diaphragm spring toe height.
Uneven limit:
KA24DE: 0.7 mm (0.028 inch)
VG33E: 0.5 mm (0.0020 inch)
- If out of limit, adjust the height with Tool.

FLYWHEEL INSPECTION

CAUTION: Do not allow any magnetic materials to contact the ring gear teeth.

- Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.





- Check flywheel runout.
Maximum allowable runout: Refer to Engine; Specifications.

Installation
- Apply recommended grease to contact surface of splines.
- Too much lubricant may damage clutch disc facing.
- Insert Tool into clutch disc hub when installing clutch cover and disc.
- Be careful not to allow grease to contaminate clutch facing.





- Tighten bolts in numerical order, in two steps.
First step: 10 - 20 Nm (1.0 - 2.0 kg-m, 7 - 14 ft. lbs.)
Final step: 22 - 29 Nm (2.2 - 3.0 kg-m, 16 - 22 ft. lbs.)