Clutch: Service and Repair
CLUTCH UNITCOMPONENTS:
REMOVAL
1. REMOVE MANUAL TRANSAXLE ASSEMBLY
2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
a) Remove the fork together with the clutch release bearing from the transaxle.
3. REMOVE CLUTCH RELEASE FORK BOOT
4. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
a) Remove the bearing 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.
7. REMOVE CLUTCH COVER ASSEMBLY
a) Place matchmarks on the cover and flywheel.
b) Loosen each set bolt one turn at a time until spring tension is released.
c) Remove the 6 set bolts and pull off the cover.
NOTICE: Do not drop the clutch disc assembly.
8. REMOVE CLUTCH DISC ASSEMBLY
INSPECTION
1. INSPECT CLUTCH DISC ASSEMBLY
a) Using a vernier caliper, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 inch)
If the depth is less than the minimum, replace the clutch disc assembly.
b) Install the disc on the transaxle.
NOTICE: Take care not to insert the clutch disc assembly in the wrong direction.
c) Using a dial gauge, measure the disc runout.
Maximum runout: 0.8 mm (0.031 inch)
If the runout is greater than the maximum, replace the clutch disc assembly.
2. INSPECT CLUTCH COVER ASSEMBLY
a) Using a vernier caliper, measure the diaphragm spring for depth and width of wear.
Maximum wear
Maximum wear:
If the wear is greater than the maximum, replace the clutch cover assembly.
3. INSPECT FLYWHEEL SUB-ASSEMBLY
a) Using a dial gauge, measure the flywheel runout.
Maximum runout: 0.1 mm (0.004 inch)
If the runout is greater than the maximum, replace the flywheel sub-assembly.
4. 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.
INSTALLATION
1. INSTALL CLUTCH DISC ASSEMBLY
a) Insert SST in the disc, then insert them in the flywheel.
SST 09301-00210
NOTICE: Take care not to insert the clutch disc in the wrong direction.
2. INSTALL CLUTCH COVER ASSEMBLY
a) Align the matchmark on the cover with that on the flywheel.
b) Following the procedures shown in the illustration, tighten the 6 bolts in order, and start with the bolt located near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
HINT:
^ Following the order in the illustration, tighten the bolts one at a time evenly.
^ 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
3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
a) Using a dial indicator with the roller instrument, measure the diaphragm spring tip alignment.
Maximum misalignment: 0.5 mm (0.020 inch)
If the alignment is greater than the maximum, use SST to adjust the diaphragm spring tip alignment.
SST 09333-00013
4. INSTALL RELEASE FORK SUPPORT
a) Install the release fork support on the transaxle.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
5. INSTALL CLUTCH RELEASE FORK BOOT
6. INSTALL RELEASE BEARING HUB CLIP
7. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a) Apply release hub grease to the contact surfaces of the release fork and release bearing, fork and push rod, and fork and fork support.
Release hub grease: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b) Install the fork to the release bearing.
8. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
a) Apply clutch spline grease to the input shaft spline.
Clutch spline grease: Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent
b) Install the bearing with release fork to the transaxle.
NOTICE: After the installation, move the fork forward and backward to check that the release bearing slides smoothly.
9. INSTALL MANUAL TRANSAXLE ASSEMBLY