Clutch: Service and Repair

CLUTCH UNIT

COMPONENTS:

REMOVAL
1. REMOVE MANUAL TRANSAXLE ASSEMBLY
a. Remove the transaxle.





2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Remove the clutch release fork with the clutch release bearing from the transaxle.
3. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
a. Remove the clutch release bearing 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.





7. REMOVE CLUTCH COVER ASSEMBLY
a. Put matchmark on the clutch cover and flywheel.
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.

NOTICE: Do not drop the clutch disc.

8. REMOVE CLUTCH DISC ASSEMBLY

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

9. INSPECT CLUTCH DISC ASSEMBLY





a. Using a vernier caliper, measure the rivet head depth.

Minimum rivet depth: 0.3 mm (0.012 inch)
If depth is less than the minimum, replace the clutch disc assembly.
b. Install the clutch disc to the transaxle.

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





c. Using a dial indicator, measure the clutch disc runout.

Maximum runout: 0.8 mm (0.031 inch)
If the runout is greater than the maximum, replace the clutch disc assembly.





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





11. INSPECT FLYWHEEL SUB-ASSEMBLY
a. Using a dial indicator, measure the flywheel runout.
Maximum runout: 0.1 mm (0.004 inch)
If runout is greater than the maximum, 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 (contact surfaces with the clutch cover) while applying force in the axial direction.
b. Inspect the clutch release bearing for damage or wear.

HINT: If necessary, replace the release bearing assembly.

INSTALLATION





1. INSTALL CLUTCH DISC ASSEMBLY
a. Insert SST in the clutch, and then insert them in the flywheel. SST 09301-00220

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





2. INSTALL CLUTCH COVER ASSEMBLY
a. Align the matchmarks on the clutch cover and flywheel.
b. Install and tighten the 6 bolts as described below.
1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
2. Uniformly tighten the 6 bolts relative to the position of the first bolt to be tightened. Use the illustration as a reference.
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.





3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
a. Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch)
If the alignment is greater than the maximum, adjust the diaphragm spring tip alignment using SST.
SST 09333-00013
4. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the transaxle.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)





5. 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 support.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b. Install the release fork to the release bearing.
c. Install the release bearing hub clip.





6. 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.

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

7. INSTALL CLUTCH RELEASE FORK BOOT
8. INSTALL MANUAL TRANSAXLE ASSEMBLY
a. Install the transaxle.