Clutch Disc: 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 FORK BOOT
4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
a. Remove the clutch release bearing assembly from the clutch release fork.
5. REMOVE RELEASE BEARING HUB CLIP
6. REMOVE RELEASE FORK SUPPORT
a. Remove the support and release fork from the transaxle assembly.





7. REMOVE CLUTCH COVER ASSEMBLY
a. Align the matchmark on the clutch cover assembly with the one on 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





9. INSPECT CLUTCH DISC ASSEMBLY
a. Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assembly as necessary.
b. Install the clutch disc assembly on the transaxle assembly.

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





c. Using a dial gage, check the clutch disc assembly runout.
Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assembly as necessary.





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





11. INSPECT FLYWHEEL SUB-ASSEMBLY
a. Using a dial gauge, inspect the flywheel sub-assembly for runout.
Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub-assembly as necessary.





12. INSPECT CLUTCH RELEASE BEARING ASSEMBLY
a. Check that the bearing moves smoothly without abnormal resistance by turning the sliding parts of the bearing (contact surfaces with the clutch cover) while applying force in the axial direction.
b. Inspect the bearing for damage or wear.
If necessary, replace the release bearing assembly.
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 09301-00210

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





14. INSTALL CLUTCH COVER ASSEMBLY
a. Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.
b. Tighten the 6 bolts in order, starting from the bolt located near the knock pin on the top as shown in the illustration.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)

HINT:
^ Following the order in the illustration, tighten the bolts little by little each time.
^ Move SST up and down, right and left lightly after checking that the disc is in the center to tighten the bolts.

SST 09301-00210





15. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
a. Using a dial gauge with the roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)





b. If alignment is not as specified, adjust it by using SST.
SST 09333-00013
16. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support on the transaxle assembly.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
17. INSTALL CLUTCH RELEASE FORK BOOT
18. INSTALL RELEASE BEARING HUB CLIP





19. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Apply release hub grease to the contact surfaces of the release fork and release bearing assembly, the release fork and push rod and the release fork and fork support.
Sealant: Part No. 08887-01806, Release Hub Grease or equivalent
b. Install the release fork on the release bearing assembly.
20. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
a. Apply the clutch spline grease to the input shaft spline.
Sealant: Part No. 08887-01706, Clutch Spline Grease or equivalent
b. Install the bearing on the release fork first and then install them on the transaxle assembly.

NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly.

21. INSTALL MANUAL TRANSAXLE ASSEMBLY