Clutch Release Fork: Service and Repair

Release Bearing and Lever

REMOVAL

5MT MODEL
1) Remove the transmission assembly from vehicle body.

2) Remove the two clips from the release lever and remove the release bearing. (Non-turbo model)

CAUTION: Be careful not to deform the clips.

3) Remove the release bearing from the clutch release lever. (Turbo model)
4) Remove the dust cover.





5) Remove the lever spring from the pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever.





6MT MODEL
1) Remove the transmission assembly from vehicle body.
2) Remove the release lever from the transmission.
3) Install the release bearing to the engine side.
4) Using a flat tip screwdriver, remove the release bearing from the clutch cover.





INSTALLATION

5MT MODEL

NOTE: Apply the specified grease to lubricate the following points before installation.
^ Contact surface of lever and pivot
^ Contact surface of lever and bearing
^ Transmission main shaft spline (Use grease containing molybdenum disulphide.)

1) While pushing the release lever to the pivot and twisting it to both sides, fit the lever spring onto the raised portion of the pivot.

NOTE:
^ Apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of the release lever and operating cylinder.
^ Observing from the main case hole, check that the lever spring is installed securely.





2) Install the release bearing and fasten it with two clips. (Non-turbo model)
3) Install the release bearing. (Turbo model)
4) Install the dust cover.





5) Check the bearing for smooth movement by operating the release lever.
6) Install the transmission assembly.


6MT MODEL
1) Attach the release bearing to the transmission.
2) Insert the release lever into the release bearing tab.





3) Apply grease to splines.





4) Insert the release shaft into the release lever.

NOTE: Make sure the cut portion of the release shaft comes into contact with the spring pin.





5) Tighten the plugs.





6) Check the release bearing and release lever for smooth movement by operating the release lever.
7) Install the transmission assembly.

INSPECTION

RELEASE BEARING

NOTE: Since this bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or any other solvent when servicing the clutch.

1) Check the bearing for smooth movement by applying force to the bearing in the radial direction.





2) While applying force to the bearing in the rotational direction, check the bearing for smooth rotation.





3) Check for wear and damage at the bearing case surface in contact with the lever.

RELEASE LEVER
Check the pivot portion of the lever and the contact area with the release bearing case for wear.