Clutch: Service and Repair

CLUTCH UNIT (MTM)
OVERHAUL
1. REMOVE MANUAL TRANSAXLE ASSEMBLY





2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Remove the clutch release fork with the clutch release bearing from the transaxle assembly.
3. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
a. Remove the clutch release bearing assembly from the clutch release fork.
4. REMOVE RELEASE BEARING HUB CLIP
5. REMOVE CLUTCH RELEASE FORK BOOT
6. REMOVE RELEASE FORK SUPPORT
a. Remove the release fork support from the transaxle assembly.





7. REMOVE CLUTCH COVER ASSEMBLY
a. Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.
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 assembly.

NOTICE: Do not drop the clutch disc assembly.

8. 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.





9. INSPECT CLUTCH DISC ASSEMBLY
a. Using vernier calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 inch)
If necessary, replace the clutch disc assembly.
b. Install the clutch disc assembly to the transaxle assembly.

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 necessary, replace the clutch disc assembly.





10. INSPECT CLUTCH COVER ASSEMBLY
a. Using vernier calipers, inspect the diaphragm spring for the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 inch)
B (Width): 6.0 mm (0.236 inch)
If necessary, replace the clutch cover assembly.





11. INSPECT FLYWHEEL SUB-ASSEMBLY
a. Using a dial indicator, inspect the flywheel sub-assembly run out.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel sub-assembly.





12. INSPECT CLUTCH RELEASE BEARING ASSEMBLY
a. Check that the clutch release bearing assembly moves smoothly without abnormal resistance by turning the sliding parts of the clutch release bearing assembly (contact surfaces with the clutch cover) while applying force in the axial direction.
b. Inspect the clutch release bearing assembly for damage or wear.

HINT: Replace the release bearing assembly as necessary.





13. INSTALL CLUTCH DISC ASSEMBLY
a. Insert SST in the clutch disc assembly, then insert them in the flywheel sub-assembly.
SST 09301-00220

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





14. INSTALL CLUTCH COVER ASSEMBLY
a. Align the matchmarks on the clutch cover assembly and flywheel sub-assembly.
b. Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting from the bolt locating near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)

HINT:
- Evenly tighten the bolts by following the order shown in the illustration.
- Tighten the bolts after checking that the disc is in the center by lightly moving the SST up and down, left and right.





15. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
a. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
Maximum nonalignment: 0.5 mm (0.020 inch)
If alignment is not as specified, adjust the diaphragm spring tip alignment using SST.
SST 09333-00013
16. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the transaxle assembly.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)





17. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Apply release hub grease to the contact surfaces of, the release fork and release bearing assembly, release fork and push rod, and release fork and fork support.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b. Install the release fork to the release bearing assembly.
c. Install the release bearing hub clip.





18. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
a. Apply clutch spline grease to the input shaft spline as shown in the illustration.
Sealant: Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent
b. Install the release fork with the release bearing assembly to the manual transaxle assembly.

NOTICE: After installation, move the fork back and forth to check that the release bearing slides smoothly.

19. INSTALL CLUTCH RELEASE FORK BOOT
20. INSTALL MANUAL TRANSAXLE ASSEMBLY