Clutch Disc: Service and Repair

CLUTCH COVER AND DISC





COMPONENTS

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





2. Remove the clutch 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 release lever.

NOTE: It is impossible to remove the transaxle assembly without performing this step because the clutch cover assembly, release bearing and release fork are held together.

3. Loosen the bolts attached to the release cylinder and remove the release cylinder.
4. Remove the transaxle assembly, after removing each bolt which connects the transaxle assembly and engine.





5. If the clutch cover is attached to the flywheel, remove the release bearing using snap-ring pliers.
1) Rotate the release bearing in an easy direction in order to examine the snap ring.
2) Insert the pliers under the wave washer as shown in the illustration and place it in the center of the snap nag.
3) Spread the snap ring by pushing down on the bearing as shown in the illustration.





4) The snap ring expanded state is shown in the figure.
5) With In the snap ring expanded, pull out the release bearing and remove it.
6. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from shifting.
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.

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

8. Remove the release fork shaft and bushing.

INSPECTION
CLUTCH COVER ASSEMBLY
1. Clean the dust from the clutch housing using a vacuum or cloth. Do not use compressed air. Check for oil leakage from the engine rear bearing oil seal and transaxle front oil seal. If leaky, repair them.
2. The friction surface of the pressure plate must be uniform over the entire disc surface. If any part shows excessive wear, the pressure plate is installed badly.
3. Check the friction surface of the flywheel for color change, partial damage, small cracks, and wear.





4. Don't touch the clutch disc with contaminated hands or gloves. Replace the clutch disc if the facing is stained with oil or grease. Measure the rivet depth. Replace the clutch disc if the rivet depth is less than 0.3 mm.
Limit: 0.3 mm (0.012 inch)
5. Check the hub spline and torsion spring of the clutch disc for excessive wear.
6. Clean the friction surface of the pressure plate with cleaning solvent.
7. Check that the three-dowel on the flywheel is installed completely.

CLUTCH RELEASE BEARING

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

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

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 the disc. Grease: CASMOLY L 9508

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

2. Install the clutch disc assembly to the flywheel using the 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
Single mass flywheel; 15 - 22 Nm (150 - 220 kg-cm, 11 - 16 ft. lbs.)
Dual mass flywheel; 20 - 27 Nm (200 - 270 kg cm, 14 - 19 ft. lbs.)





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

CAUTION: Apply multipurpose grease (CASMOLY L9508) to the bearing sleeve and contact point of the release fork.





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

CAUTION: If the transaxle assembly is installed to the engine without performing this step, the release bearing can be separated, as the release fork rotates freely.





7. After finishing step 6, push the release lever to the arrow mark. If there is a click sound, the release bearing and clutch cover are aligned correctly. If the Assembly does not snap into place, start with step 1 again.
8. Release lever operating range is 3° or less. If the range is over 3°, the release bearing and clutch cover are not aligned correctly. Push the release lever to the arrow mark one more time.