Pressure Plate and Clutch Disc Removal
Clutch ReplacementSpecial Tools Required
^ Clutch alignment shaft 07LAF-PT00110
^ Clutch alignment disc 07JAF-PM7011A
^ Remover handle 07936-3710100
^ Ring gear holder 07LAB-PV00100 or 07924-PD20003
^ Attachment, 57 x 40 mm 07746-0010200
^ Driver 077 49-0010000
Pressure Plate and Clutch Disc Removal
1. Check the diaphragm spring fingers for height using the special tools and a feeler gauge (A). If the height is more than the service limit, replace the pressure plate.
Standard (New): 0.6 mm (0.02 inch) max.
Service Limit: 1.0 mm (0.04 inch)
2. Install the special tools.
3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B).
4. Inspect the pressure plate (A) surface for wear, cracks, and burning.
5. Inspect the fingers of the diaphragm spring (B) for wear at the release bearing contact area.
6. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate.
Standard (New): 0.03 mm (0.001 inch) max.
Service Limit: 0.15 mm (0.006 inch)
7. Remove the clutch disc and special tools.
8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc is burned black or oil soaked, replace it.
9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.
Standard (New):
'01 model: 8.3 - 9.0 mm (0.33 - 0.35 inch) max.
'02-03 models: 8.5 - 9.1 mm (0.34 - 0.36 inch) max.
Service Limit:
'01 model: 5.7 mm (0.22 inch)
'02-03 models: 5.8 mm (0.23 inch)
10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc.
Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 inch) max.
Service Limit: 0.8 mm (0.03 inch)