Clutch: Service and Repair

CLUTCH UNIT (MTM)
OVERHAUL
1. REMOVE MANUAL TRANSAXLE ASSY





2. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a. Remove the clutch release fork with the clutch release bearing from the transaxle assy.
3. REMOVE CLUTCH RELEASE FORK BOOT
4. REMOVE CLUTCH RELEASE BEARING ASSY
a. Remove the clutch release bearing assy from the clutch release fork.
5. REMOVE RELEASE BEARING HUB CLIP
6. REMOVE RELEASE FORK SUPPORT
a. Remove the support and release fork from the transaxle assy.





7. REMOVE CLUTCH COVER ASSY
a. Align the matchmark on the clutch cover assy with the one on the flywheel sub-assy.
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 assy.

NOTICE: Do not drop the clutch disc assy.

8. REMOVE CLUTCH DISC ASSY





9. INSPECT CLUTCH DISC ASSY
a. Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 inch)
Replace the clutch disc assy as necessary.
b. Install the clutch disc assy on the transaxle assy.

NOTICE: Take care not to insert the clutch disc assy in the wrong direction.





c. Using a dial gage, check the clutch disc assy runout.
Minimum runout: 0.8 mm (0.031 inch)
Replace the clutch disc assy as necessary.





10. INSPECT CLUTCH COVER ASSY
a. Using vernier calipers, inspect the diaphragm spring for depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 inch)
B (Width): 6.0 mm (0.236 inch)
Replace the clutch cover assy as necessary.





11. INSPECT FLYWHEEL SUB-ASSY
a. Using a dial gage, inspect the flywheel sub-assy runout.
Maximum runout: 0.1 mm (0.004 inch)
Replace the flywheel sub-assy as necessary.





12. INSPECT CLUTCH RELEASE BEARING ASSY
a. Turn the release bearing by hand while applying force in the axial direction.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. Replace the release bearing assy as necessary.





13. INSTALL CLUTCH DISC ASSY
a. Insert SST in the clutch disc assy, then insert them in the flywheel sub-assy.
SST 09301-00210

NOTICE: Take care not to insert clutch disc assy in the wrong direction.





14. INSTALL CLUTCH COVER ASSY
a. Align the matchmark on the clutch cover assy with that on the flywheel sub-assy.
b. Following the procedures shown in the illustration, tighten the 6 bolts in order, and start the bolt locating near the knock pin on the top.
Torque: 19 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 to tighten the bolts.

SST 09301-00210





15. INSPECT AND ADJUST CLUTCH COVER ASSY
a. Using a dial indicator with the roller instrument, check the diaphragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 inch)





b. If alignment is not as specified, using SST to adjust the diaphragm spring tip alignment.
SST 09333-00013
16. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support on the transaxle assy.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
17. INSTALL CLUTCH RELEASE FORK BOOT
18. INSTALL RELEASE BEARING HUB CLIP





19. INSTALL CLUTCH RELEASE FORK SUB-ASSY
a. Apply release hub grease to the release fork and release bearing assy contact, the release fork and push rod contact and the release fork pivot points.
b. Install the release fork on the release bearing assy.
20. INSTALL CLUTCH RELEASE BEARING ASSY
a. Apply the clutch spline grease to the input shaft spline.
b. Install the bearing on the release fork first and then install them on the transaxle assy.

NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly.

21. INSTALL MANUAL TRANSAXLE ASSY