Flywheel: Service and Repair
CLUTCH UNIT REMOVAL/INSTALLATION
1. Remove the battery cover. Removal and Replacement
2. Disconnect the negative battery cable.
3. Remove the following parts:
a. Battery and battery tray Removal and Replacement
b. Air cleaner component Service and Repair
c. Exhaust manifold insulator
d. Windshield wiper arm and blade Windshield Wiper Arm and Blade Removal/Installation
e. Cowl grille Cowl Grille Removal/Installation
f. Cowl panel Cowl Panel Removal/Installation
g. Wheels, tires and splash shields
h. Under cover
i. Starter Removal and Replacement
j. No.1 reserve tank with the hoses still connected and position the No.1 reserve tank aside so that it is out of the way Service and Repair
k. Reserve tank bracket Service and Repair
4. Drain the transaxle oil into a suitable container. Transaxle Oil Replacement
5. Remove the manual transaxle. Manual Transaxle Removal/Installation
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Add the specified amount of specified transaxle oil. Transaxle Oil Replacement
NOTE:
- If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE OVERHAUL" and verify that there is no abnormality.
Inspection After Transaxle Overhaul
Clutch Release Fork Removal Note
1. Remove the fork supporter before disassembling the release fork.
Clutch Cover and Disc Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
Pilot Bearing Removal Note
NOTE:
- The pilot bearing does not need to be removed unless you are replacing it.
1. Use the SSTs to remove the pilot bearing.
Pilot Bearing Installation Note
1. Install the pilot bearing using the corresponding 20 mm {0.79 in} side of a Snap-on brand millimeter size bushing driver set A160M adapter A160M7 (20-22 mm {0.79-0.86 in}) or substitution tool.
Substitution tool
- Outer diameter: 21 mm {0.83 in}
- Inner diameter: 19 mm {0.75 in}
Flywheel Removal Note
1. Hold the flywheel using the SST.
2. Remove the bolts evenly and gradually in a crisscross pattern.
3. Remove the flywheel.
4. Inspect for oil leakage from the crankshaft rear oil seal.
- If there is any malfunction, replace the crankshaft rear oil seal. Service and Repair
Flywheel Installation Note
1. Install the flywheel to the crankshaft.
2. Clean the crankshaft thread holes before installing the new lock bolts.
3. Hand-tighten the flywheel lock bolts.
4. Install the SST to the flywheel.
5. Gradually tighten the flywheel lock bolts in a crisscross pattern.
Tightening torque
- 108-116 Nm {11.1-11.8 kgf-m, 79.7-85.5 ft-lbf}
Clutch Disc Installation Note
1. Hold the clutch disc position using the SST.
Clutch Cover Installation Note
1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a crisscross pattern.
Tightening torque
- 25-33 Nm {2.6-3.4 kgf-m, 18.5-24.4 ft-lbf}