Clutch: Service and Repair

CLUTCH COVER AND DISC





COMPONENTS

REPLACEMENT
1. Remove the transaxle assembly.





2. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from failing.





3. 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 the release bearing with cleaning solvent.

4. Remove the release fork shaft and bushing.





5. Apply multipurpose grease to the spline of the disc.
Grease: CASMOLY L 9508 0.2gr

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.

6. Install the clutch disc assembly to the flywheel using the special tool (09411-11000).





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





8. 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, contact point of the release fork (B) and the bushing Inner surface (C).





9. Install the release lever to the release fork.
10. 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.