Clutch Assembly

REMOVAL
1. Transmission assembly.
2. Pressure plate assembly.





3. Driven plate assembly, as follows:
a. Use the clutch pilot aligner to prevent the driven plate assembly from falling free.
Clutch pilot aligner: J-24547 or equivalent.
b. Mark the flywheel, clutch cover and pressure plate lug for alignment when installing.





c. Loosen the clutch cover bolts in the numerical order shown in the illustration.
4. Release bearing.

NOTE: The release bearing is permanently packed with lubricant and should not be soaked in cleaning solvent, as his will dissolve the lubricant.

5. Shift fork
6. Flywheel assembly and bearing crankshaft, as follows:
a. Do not remove except for replacement.





b. Remove the bearing using remover.
Remover: J-5822 or equivalent.
Sliding hammer: J-23907 or equivalent.

INSPECTION AND REPAIR
Make necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered during inspection.

Pressure Plate Assembly
Visually inspect the pressure plate friction surface for excessive wear and heat cracks. If excessive wear or deep heat cracks are present, the pressure plate must be replaced.

Pressure Plate Width





Use a vernier caliper to measure the pressure plate width (A).
Pressure plate width:
Standard: 10 mm (0.39 inch).

Pressure Plate Warpage





Use a straight edge and a feeler gauge to measure the pressure plate friction surface flatness in four directions. If any of the measured values exceed the specified limit, the pressure plate must be replaced.
Pressure plate warpage:
Limit: 0.3 mm (0.012 inch).

Clutch Cover





Visually inspect the entire clutch cover for excessive wear, cracking, and other damage. The clutch cover must be replaced if any of these conditions are present.

Clutch Set Force





1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate. A metal sheet with (A) thickness of 8.0 mm (0.315 inch) may be used in place of the driven plate.
3. Compress the pressure plate assembly until the distance 3 becomes 4 mm (0.157 inch).
4. Note the pressure gauge reading.
Clutch set force:
Standard: 5488 N (1235 lbs.).

Diaphragm Spring Finger Height
1. Place a 8.0 mm (0.315 inch) spacer beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm spring. There are two ways to do this.
a. Use a bench press to press down on the assembly from the top.
b. Tighten the fixing bolts.





3. Measure the spring finger height from base to spring tip (A). If the measured value exceeds the specified limit, the pressure plate assembly must be replaced.
Spring finger height:
Standard: 37.5 - 39.5 mm (1.48 - 1.56 inch).

Shift Fork





1. Visually inspect the surfaces of the shift fork making contact with the shift block.
2. Remove any minor stepping or abrasion from the shift block with an oil stone.

Driven Plate Assembly





1. Visually inspect the torsion spring (1) for looseness, breakage, and weakening. If any of these conditions are discovered, the driven plate assembly must be replaced.
2. Visually inspect the facing surfaces (2) for cracking and excessive scorching. Visually inspect the facing surfaces for the presence of oil or grease. If any of these conditions are discovered, the facing must be cleaned or replaced.
3. Check that the driven plate moves smoothly on the transmission top gear shaft spline. Minor ridges on the top gear shaft spline may be removed with an oil stone.

Driven Plate Warpage
1. Insert the clutch pilot aligner into the driven plate splined hub. The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner: J-24547 or equivalent.





2. Set a dial indicator to the driven plate outside circumference.
3. Slowly turn the driven plate. Read the dial indicator as you turn the driven plate. If the measured value exceeds the specified limit, the driven plate assembly and/or the facing must be replaced.
Driven plate warpage:
Standard: 0.7 mm (0.028 inch)
Limit: 1.0 mm (0.039 inch).

Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft spline.
3. Set a surface gauge to the driven plate outside circumference.





4. Slowly turn the driven plate counterclockwise. Measure the spline rotation play as you turn the driven plate. If the measured value exceeds the specified limit, the driven plate assembly must be replaced.
Driven plate splined hub spline wear:
Standard: 0.5 mm (0.020 inch).
Limit: 1.0 mm (0.039 inch).

Rivet Head Depression





Use a depth gauge or a straight edge with steel rule to measure the rivet head depression (1) from the facing surface (2). Be sure to measure the rivet head depression on both sides of the driven plate. If the measured value is less than the specified limit, the facing must be replaced.
Rivet head depression:
Standard: Minimum 1.3 mm (0.051 inch)
Limit: 0.2 mm (0.008 inch).

Pressure Plate Assembly





Check the cover for cracks and distortion, and the diaphragm spring for heat distortion, loosened rivets. Check the wire ring for wear.

INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points, as follows:





1. Flywheel assembly and bearing crankshaft (6).
- Clean and lubricate with grease.
Installer: J-2651 6-A or equivalent.
Grip: J-8092 or equivalent.





2. Bolts: flywheel fixing, as follows:
a. When reinstalling the flywheel on the crankshaft which has been in use, remove all traces of LOCTITE from the bolt holes in the crankshaft by turning in the new bolt, then clean the crankshaft with cleaner before installing the flywheel.
b. Install new bolts after applying LOCTITE 262 in the order illustrated and tighten them in sequence.
Torque: 59 Nm (43 ft. lbs.).
c. Use of excessive amount of LOCTITE will result in dripping into the engine crankcase or reduction in the clamping force.
3. Shift fork (5).
- Coat the rounded end of the ball stud with grease.





4. Release bearing (4)
- Pack the inside recess (A) and coat the outside groove (B) of the release bearing with grease.





5. Driven plate assembly (3)
Aligner: J-24547 or equivalent.





6. Pressure plate assembly (2)
- Tighten the bolts holding the pressure plate assembly in the order shown.
Torque: 18 Nm (13 ft. lbs.).
- Remove the aligner.

NOTE: Do not strike the aligner with a hammer to remove it.

7. Transmission assembly (1).





Shift Fork Lubrication

Legend:
a. Clutch housing
b. Plug
c. Ball stud
d. Shift fork
1. Remove the plug from the clutch housing.
2. Lubricate the shift fork through a lubrication hole of ball stud with grease using a grease gun.
3. Install the plug to the clutch housing.