Clutch Disc: Service and Repair

CLUTCH COVER AND DISC COMPONENTS






REMOVAL

1. To remove the transaxle assembly firstly remove the air cleaner joint, mounting bracket, and wiring etc.

2. Remove the release lever.






1) Loosen the release lever nut and washer
2) Remove the clevis pin and snap ring from the release cylinder.
3) Remove the retease lever.

NOTE: It is impossible to remove transaxle assembly without doing this step. Because, clutch cover, release bearing and release fork are combined together.

3. Remove the release cylinder
4. Remove the transaxle assembly.






5. Remove the release bearing using appropriate tool as shown.






1) Insert the tool under the wave washer
2) Widen the space of snap ring by pushing the bearing as shown. As above state, pull the bearing and remove it.






6. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling
7. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

NOTE: Do not clean the clutch disc or release bearing with cleaning solvent.

8. Remove the bushing and release fork shaft.

INSPECTION

CLUTCH COVER ASSEMBLY

1. Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit.

Limit: 0.5 mm (0.012 in)

2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.

CLUTCH DISC






1. Check the facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil or grease and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification

Limit: 0.3 mm (0.012 in)

3. Check for torsion spring play and damage and it defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.lf the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING

CAUTION: The release bearing is packed with grease. Do not use cleaning solvent or oil.

1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.

CLUTCH RELEASE FORK

If there is abnormal wear at the point of contact with the bearing, replace the release fork.

INSTALLATION






1. Apply multipurpose grease to the spline of disc.
Grease: MOLYWHITE TA No.2

CAUTION: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; It can cause clutch slippage and shudder.






2. Install the clutch disc assembly to the flywheel using special tool (09411-11000).
3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star pattern.
Tightening torque: clutch cover bolt 15-22 Nm (150-220 kg.cm, 11-16 lb.ft)






4. Align the bearing to the release fork and then install it to the sleeve of housing.

CAUTION: Apply multipurpose grease (MOLYWHITH TA No.2) to the grease home of bearing sleeve and contact point of release fork.






5. Install the release lever to the release fork.
6. Install the transaxle assembly to the engine






7. After finishing step 6, pushing the release lever to the arrow mark it is sounded click that the release bearing and clutch cover are aligned correctly.
Release lever operating range : 3° or less

If the range is over 3° it is a symptom that the release bearing and clutch cover are not aligned correctly. So push the release lever to the arrow mark one more time.