Clutch: Service and Repair

Clutch Replacement

Special Tools Required
^ Clutch alignment shaft 07LAF-PT00110
^ Remover handle 07936-3710100
^ Ring gear holder 07LAB-PV00100 or 07924-PD20003
^ Driver 07749-0010000
^ Attachment, 32 x 37 mm 07746-0010200

Pressure Plate and Clutch Disc Removal





1. Check the diaphragm spring fingers for height variation using the dial indicator (A). If the variation is more than the service limit, replace the pressure plate.
Standard (New): 0.4 mm (0.016 inch) maximum
Service Limit: 0.6 mm (0.024 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. Remove the release bearing (C) from the pressure plate.





5. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
6. Inspect the pressure plate surface for wear, cracks, and burning.





7. 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) maximum
Service Limit: 0.15 mm (0.006 inch)





8. Remove the clutch disc and special tools.
9. 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.





10. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.
Standard (New): 8.2 - 8.9 mm (0.32 - 0.35 inch)
Service Limit: 6.0 mm (0.24 inch)








11. Measure the rivet depth from the lining surface (A) to rivets (B), on both sides. If the rivet depth is less than the service limit, replace the clutch disc.
Standard (New): 1.2 - 1.7 mm (0.047 - 0.067 inch)
Service Limit: 0.2 mm (0.008 inch)

Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.





3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Resurfacing the flywheel is not recommended.
Standard (New): 0.05 mm (0.002 inch) maximum
Service Limit: 0.15 mm (0.24 inch)





4. Turn the inner race of the ball bearing (A) with your finger. The ball bearing should turn smoothly and quietly. Check that the ball bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the ball bearing.

Flywheel Replacement





1. Install the special tool.
2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.





3. Remove the ball bearing (A) from the flywheel (B).





4. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface.
5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and mounting bolts finger-tight.





6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps.

Release Bearing Inspection





Check the release bearing for excessive play by spinning it by hand, if there is excessive play, replace the release bearing with a new one.

NOTE: The release bearing is packed with grease. Do not wash it in solvent.

Clutch Disc and Pressure Plate Installation





1. Apply a thin, uniform coat of Super High Temp Urea Grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Slide the clutch disc onto the mainshaft, and remove extra overflow grease.
2. Install the ring gear holder.
3. Install the clutch disc using the special tools.





4. Apply Super High Temp Urea Grease (P/N 08798-9002) into the groove (A) of the release bearing (B), then install the release bearing on the pressure plate (C).
5. Install the pressure plate and the mounting bolts (D) finger-tight. Make sure the release bearing does not come off.

25 Nm (19 Ft Lbs):

6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.
PRESSURE PLATE MOUNTING BOLT TORQUE: 25 Nm (2.6 kgf-m, 19 ft. lbs.)
7. Remove the special tools.
8. Make sure the diaphragm spring fingers are all the same height.