Clutch: Service and Repair

REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE





2. REMOVE CLUTCH COVER AND DISC
a. Place matchmarks on the flywheel and clutch cover.
b. Loosen each set bolt one turn at a time until spring tension is released.
c. Remove the set bolts, and pull off the clutch cover with the clutch disc.

NOTICE: Do not drop the clutch disc.





3. REMOVE BOOT, RELEASE BEARING AND FORK FROM TRANSMISSION
a. Remove the boot from the transmission.
b. Remove the release bearing together with the fork and then separate them.
c. Remove the clip from the release bearing.

INSPECTION





1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using vernier calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 inch)
If it is not as specified, replace the clutch disc.





2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator with roller instrument, check the disc runout.
Maximum runout: 0.8 mm (0.031 inch)
If it is not as specified, replace the clutch disc.





3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator with roller instrument, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 inch)
If it is not as specified, replace the flywheel.





4. INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the axial direction.
If the bearing sticks or has much resistance, replace the pilot bearing.
5. IF NECESSARY, REPLACE PILOT BEARING





a. Remove the 2 bolts at diametrically opposite points.





b. Using SST, remove the pilot bearing.
SST 09303-35011





c. Using SST and a hammer, drive in a new pilot bearing.
SST 09300-12012





d. Install the 2 new bolts.
e. First, torque the 2 bolts uniformly a little at a time.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
f. Then tighten the 2 bolts and additional 80 - 100°.





6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and width of wear.
Maximum depth: A 0.6 mm (0.024 inch)
Maximum width: B 5.0 mm (0.197 inch)
If it is not as specified, replace the clutch cover.





7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.

If necessary, replace the release bearing.

INSTALLATION





1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL
a. Insert SST in the clutch disc, and then set them.
SST 09301-00110
b. Align the matchmarks on the clutch cover and flywheel.
c. Following the procedures shown in the illustration, tighten the 6 bolts in the order starting the bolt locating near the knock pin on the top.
Torque: 19.1 Nm (195 kgf-cm, 14 ft. lbs.)

HINT:
- Following the order in the illustration, tighten the bolts at a time evenly.
- Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.





2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch)
If the alignment is not as specified, with SST, adjust the diaphragm spring tip alignment. SST 09333-00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2)





a. Apply release hub grease to the release fork and release bearing contact, release fork and push rod contact and release fork pivot points.





b. Apply clutch spline grease to the clutch disc spline.

HINT: Recommended grease part number 08887-01706 (100 g).

4. INSTALL BOOT, RELEASE BEARING AND FORK TO TRANSMISSION
a. Install the clip to the release bearing.
b. Install the release bearing to the release fork, and then install them to the transmission.
c. Install the boot to the transmission.
5. INSTALL TRANSMISSION TO ENGINE