Clutch Disc: Service and Repair

REMOVAL
1. To remove the transaxle assembly, first drain the clutch fluid and transaxle gear oil, then remove the air cleaner joint and the mounting bracket etc.





2. Remove the clutch release lever (A).
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 (A).





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 ring.





3. Spread the snap ring by pushing down on the bearing as shown in the illustration.





4. The snap ring (A) at expanded state is shown in the figure.
5. In the snap ring expanded, pull out the release bearing and remove it.
6. Insert the special tool (09411-25000) 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. Check the diaphragm spring end for wear and uneven height.
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 clutch 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 thickness of the disc when free.
3. Check for the torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If 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 assembly.

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 shudder.

2. Install the clutch disc assembly to the flywheel using the special tool (09411-25000).





3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star



4. Align the bearing (A) to the release fork (B) 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.
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.