Clutch: Service and Repair

CLUTCH UNIT
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 BEARING ASSEMBLY
a) Remove the release bearing hub clip and clutch release bearing assembly from the clutch release fork.
4. REMOVE RELEASE FORK SUPPORT
a) Remove the release fork support from the manual transaxle assembly.
5. REMOVE CLUTCH RELEASE FORK BOOT
6. REMOVE CLUTCH COVER ASSEMBLY





a) Put matchmarks on the clutch cover assembly and 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.

7. REMOVE CLUTCH DISC ASSEMBLY

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

8. INSPECT CLUTCH DISC ASSEMBLY





a) Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 inch)
If necessary, replace the clutch disc assembly.





b) Install the clutch disc assembly to the transaxle assembly.

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

c) Using a dial indicator, check the clutch disc assembly for runout.
Maximum runout: 0.8 mm (0.031 inch)
If necessary, replace the clutch disc assembly.
9. 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 inch)
B (Width): 6.0 mm (0.236 inch)
If necessary, replace the clutch cover assembly.
10. INSPECT FLYWHEEL SUB-ASSEMBLY





a) Using a dial indicator, inspect the flywheel sub-assembly for runout.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel sub-assembly.
11. INSPECT CLUTCH RELEASE BEARING ASSEMBLY





a) Turn the release bearing assembly by hand while applying force in the axial direction.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.
If necessary, replace the release bearing assembly.

12. INSTALL CLUTCH DISC ASSEMBLY





a) Insert SST into the clutch disc assembly, then insert them into the flywheel sub-assembly.
SST 09301-00220

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

13. INSTALL CLUTCH COVER ASSEMBLY





a) Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.
b) Following the procedures shown in the illustration, tighten the 6 bolts starting at 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, gradually tighten the bolts one at a time.
^ Check that the disc is in the center by lightly moving SST up and down, right and left, and then tighten the bolts.

14. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY





a) Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch)
If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
SST 09333-00013
15. INSTALL RELEASE FORK SUPPORT
a) Install the release fork support to the manual transaxle assembly.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)
16. INSTALL RELEASE BEARING HUB CLIP
a) Install the release bearing hub clip to the release bearing assembly.
17. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY





a) Apply release hub grease to the release fork, release bearing assembly, push rod contact point and pivot points as shown in the illustration.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b) Install the release fork to the release bearing assembly.
18. 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 assembly.

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

19. INSTALL CLUTCH RELEASE FORK BOOT
20. INSTALL MANUAL TRANSAXLE ASSEMBLY