Clutch: Service and Repair
OVERHAUL1. REMOVE MANUAL TRANSAXLE ASSEMBLY
2. REMOVE CLUTCH RELEASE FORK BOOT
3. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
4. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
5. REMOVE RELEASE BEARING HUB CLIP
6. REMOVE RELEASE FORK SUPPORT
a. Remove the release fork support from the manual transaxle assembly.
7. REMOVE CLUTCH COVER ASSEMBLY
a. Place the matchmarks on the clutch cover assembly with the one on the 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.
8. 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 attachment.
9. 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 runout.
Minimum runout: 0.8 mm (0.031 inch)
If necessary, replace the clutch disc assembly.
10. 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 clutch cover assembly.
11. INSPECT FLYWHEEL SUB-ASSEMBLY
a. Using a dial indicator, inspect the flywheel sub-assembly run out.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel sub-assembly.
12. 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.
13. INSTALL CLUTCH DISC ASSEMBLY
a. Insert SST in the clutch disc assembly, then insert them in the flywheel sub-assembly.
SST 09301-00220
NOTICE: Take care not to insert clutch disc assembly in the wrong direction.
14. INSTALL CLUTCH COVER ASSEMBLY
a. Align the matchmarks on the clutch cover assembly and flywheel sub-assembly.
b. Following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top.
Torque: 19.1 Nm (199 kgf-cm, 14 ft. lbs.)
HINT:
- Following the order in the illustration, tighten the bolts at a time evenly.
- Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.
15. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
a. Using a dial indicator with 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
16. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the manual transaxle assembly.
Torque: 47.1 Nm (480 kgf-cm, 35 ft. lbs.)
17. INSTALL RELEASE BEARING HUB CLIP
a. Install the release bearing hub clip to the release bearing assembly.
18. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Apply release hub grease to the release fork and release bearing assembly contact, release fork and push rod contact and release fork pivot points.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b. Install the release fork to the release bearing assembly.
19. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
a. Apply the clutch spline grease to the input shaft spline.
Sealant: Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent
b. Install the release fork with release bearing assembly to the manual transaxle assembly.
NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly.
20. INSTALL CLUTCH RELEASE FORK BOOT
21. INSTALL MANUAL TRANSAXLE ASSEMBLY