Clutch: Service and Repair

Clutch Release Mechanism





- Align retaining pin with cavity of clutch housing and tap out retaining pin.

INSPECTION
- Check release bearing to see that it rolls freely and is free from noise, cracks, pitting or wear. Replace if necessary.

- Check release sleeve and withdrawal lever rubbing surface for wear, rust or damage. Replace if necessary.

LUBRICATION





- Apply recommended grease to contact surface and rubbing surface.

Note: Too much lubricant might cause clutch disc facing damage.





Clutch Disc

INSPECTION





- Check clutch disc for wear ot facing.

Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)





- Check clutch disc to backlash of spline and runout of facing.

Maximum backlash of spline (at outer edge of disc):
0.8 mm (0.031 in)
Runout limit:
0.7 mm (0.028 in)
Distance of runout check point (from hub center):
190TBL 90 mm (3.54 in)
2OOTBL 95 mm (3.74 in)

- Check clutch disc for burns, discoloration of oil or grease leakage. Replace if necessary.

INSTALLATION
- Apply recommended grease to contact surface of spline portion.

Note: Too much lubricant might cause clutch disc facing damage.

Clutch Cover and Flywheel

INSPECTION AND ADJUSTMENT





- Set Tool and check height and unevenness ot diaphragm spring

- Set O.4 mm 0.016 in feeler gauges on distance pieces (ST20050100) when checking C190S

- Set 0.1 mm (0.004 in) feeler gauges on distance pieces (ST20050100) when checking C2OOS.

Diaphragm spring height "A":
C19OS 29-31 mm (1.14-1.22 in)
C2OOS 31-33 mm (1.22-1.30 in)

- Check thrust rings for wear or damage by shaking cover assembly up and down to listen for chattering noise, or lightly hammering on rivets for a slightly cracked noise. Replace clutch cover assembly if necessary.

- Check pressure plate and clutch disc contact surface for slight burns or discoloration Repair pressure plate with emery paper,

- Check pressure plate and clutch disc contact surface for deformation or damage. Replace if necessary.

- Check flywheel and clutch disc contact surface for slight burns or discoloration. Repair flywheel with emery paper.





- Adjust unevenness of diaphragm spring with Tool.

Uneven limit:
0.5 mm (0.020 in)

Flywheel Inspection





- Check contact surface of flywheel for slight burns or discoloration. Repair flywheel with emery paper.

- Check flywheel runout.

Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)

INSTALLATION





- Insert TooL into clutch disc hub when installing clutch cover and disc.