Clutch Disc: Service and Repair

CLUTCH COVER AND DISC





COMPONENTS

REMOVAL
1. Insert the special tool (09411-43000) in the clutch disc to prevent the disc from shifting.





2. 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.

INSPECTION
CLUTCH COVER & DISC 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. Measure the flatness of the pressure plate with a square. If it exceeds 0.5 mm, replace it. Check the pressure plate surface of wear, cracks, and color change.
8. 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 points 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 (09411-43000).





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 ft. lbs.)





4. Remove guide washer (stockage plate) when install SAT cover and disc assembly on the flywheel.