Clutch Unit Overhaul
CLUTCH UNIT
OVERHAUL
1. REMOVE MANUAL TRANSAXLE ASSY
2. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a) Remove the clutch release fork with the clutch release bearing from the transaxle assy.
3. REMOVE CLUTCH RELEASE BEARING ASSY
a) Remove the release bearing hub clip and clutch release bearing assy from the clutch release fork.
4. REMOVE RELEASE FORK SUPPORT
a) Remove the release fork support from the manual transaxle assy.
5. REMOVE CLUTCH RELEASE FORK BOOT
6. REMOVE CLUTCH COVER ASSY
a) Put matchmarks on the clutch cover assy and flywheel sub-assy.
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 assy.
NOTICE: Do not drop the clutch disc assy.
7. REMOVE CLUTCH DISC ASSY
NOTICE: Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub-assy away from oil and foreign matter.
8. INSPECT CLUTCH DISC ASSY
a) Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 inch)
If necessary, replace the clutch disc assy.
b) Install the clutch disc assy to the transaxle assy.
NOTICE: Take care not to insert the clutch disc assy in the wrong direction.
c) Using a dial indicator, check the clutch disc assy for runout.
Maximum runout: 0.8 mm (0.031 inch)
If necessary, replace the clutch disc assy.
9. INSPECT CLUTCH COVER ASSY
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 assy.
10. INSPECT FLYWHEEL SUB-ASSY
a) Using a dial indicator, inspect the flywheel sub-assy for runout.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel sub-assy.
11. INSPECT CLUTCH RELEASE BEARING ASSY
a) Turn the release bearing assy 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 assy.
12. INSTALL CLUTCH DISC ASSY
a) Insert SST into the clutch disc assy, then insert them into the flywheel sub-assy.
SST 09301-00220
NOTICE: Take care not to insert the clutch disc assy in the wrong direction.
13. INSTALL CLUTCH COVER ASSY
a) Align the matchmark on the clutch cover assy with the one on the flywheel sub-assy.
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 ASSY
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 assy.
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 assy.
17. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a) Apply release hub grease to the release fork, release bearing assy, 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 assy.
18. INSTALL CLUTCH RELEASE BEARING ASSY
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 assy to the manual transaxle assy.
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 ASSY