Clutch Reassembly
ReassemblySpecial Tools Required
- Clutch spring compressor attachment 07LAE-PX40100
- Clutch spring compressor attachment 07HAE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
- Clutch compressor attachment 07ZAE-PRP0100
Note these items during reassembly:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow out all passages.
- Apply ATF to all parts before assembly.
1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Inspect the check valve (A) on the clutch pistons (B). If the check valve is loose or stuck, replace the piston.
3. Install new O-rings (A) on the piston (B).
4. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing.
NOTE: Do not pinch the O-ring by installing the piston with too much force.
5. Check the 1st-hold clutch plate-to-top-disc clearance; starting with a clutch plate, alternately install the clutch plate and discs in the 1st-hold clutch drum, then install the 1st-hold clutch plate B.
6. Measure the 1st-hold clutch clearance between the 1st-hold clutch plate B and the top disc (A) with a feeler gauge (C) while pressing the 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.
1st-hold Clutch Plate B-to-Top-disc Clearance
Service Limit: 0.5 - 0.9 mm (0.020 - 0.035 inch)
7. If the clearance is out of standard, replace the 1sthold clutch plates and discs as a set, and recheck.
8. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.
9. Install the special tools on the clutch assembly.
10. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 4th, 5th, and 1st clutches.
11. Set the special tool (A) on the spring retainer (B) of the 2nd and 3rd clutches so the tool works on the clutch return spring (C).
12. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.
13. Compress the return spring.
14. Install the snap ring (A).
15. Remove the special tools.
16. Install the disc spring in the 1st, 3rd, 4th, and 5th clutches in the direction shown.
NOTE: The 2nd clutch and 1st-hold clutch do not have a disc spring.
17. Make sure the inside of the clutch drum is free of dirt and other foreign particles.
18. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate (A), with the flat side toward the disc (B)
19. Install the snap ring (A) with a screwdriver (B).
20. Set a dial indicator (A) on the clutch end plate (B).
21. Zero the indicator with the clutch end plate lifted up to the snap ring (C).
22. Release the clutch end plate to lower clutch end plate, then put the special tool on the end plate (A).
23. Press the special tool down with 39 N (4 kgf, 9 lbs.) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use the average as the actual clearance.
Clutch End Plate-to-Top Disc Clearance:
Service Limit:
- 1st Clutch: 1.1 - 1.3 mm (0.043 - 0.051 inch)
- 2nd Clutch:
- Premium model:
0.7 - 0.9 mm (0.028 - 0.035 inch)
- TYPE S model:
0.85 - 1.05 mm (0.033 - 0.041 inch)
- 3rd Clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)
- 4th Clutch: 0.55 - 0.75 mm (0.022 - 0.030 inch)
- 5th Clutch: 0.55 - 0.75 mm {0.022 - 0.030 inch)
24. If the clearance is not within the service limit, select a new clutch end plate from the following table.
NOTE: If the thickest clutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates as a set.
1ST CLUTCH END PLATES
2ND CLUTCH END PLATES
3RD CLUTCH END PLATES
4TH and 5TH CLUTCH END PLATES