Clutch Disc: Service and Repair

CLUTCH COVER AND DISC





COMPONENTS

REMOVAL
1. Drain the clutch fluid and transaxle gear oil.
2. Remove the transaxle assembly.
3. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from falling.
4. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern.





5. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

CAUTION: DO NOT clean the clutch disc or release bearing with cleaning solvent.

INSPECTION
CLUTCH COVER ASSEMBLY
1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.

CLUTCH DISC
1. Check the facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil or grease and replace the clutch disc if defective.





2. Measure the thickness of the disc when free.
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
5. If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING

CAUTION: The release bearing is packed with grease. Do not use cleaning so/vent or oil.

1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.

CLUTCH RELEASE FORK
If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly.

INSTALLATION





1. Apply multipurpose grease to the spline of disc. Grease: MOLYWHITE TA No.2

CAUTION: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease ; It can cause clutch slippage and judder.

2. Install the clutch disc assembly to the flywheel using special tool (09411-25000).





3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star pattern.
Tightening torque
Clutch cover bolt 15 - 22 Nm (150 - 220 kg-cm, 11 - 16 ft. lbs.)





4. Align the bearing to the release fork and then install it to the sleeve of housing.

CAUTION: Apply multipurpose grease (MOLYWHITE TA No.2) to the grease groove of bearing sleeve and contact point of release fork.

5. Install the release lever to the release fork.

CAUTION: If transaxle assembly is installed to engine without doing this step, the release bearing can be separated according as the release fork rotates free.





6. Install the transaxle assembly to the engine.





7. After finishing step 6, pushing the release lever to the arrow mark it its sounded click that the release bearing and clutch cover are aligned correctly. Release lever operating range: 3� or less If the range is over 3�, it is a symptom that the release bearing and clutch cover are not aligned correctly. So, push the release lever to the arrow mark one more time.