Clutch: Service and Repair

Removal





1. Hold flywheel stationary with special tool (A) and remove clutch cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924-17810





2. Pull out input shaft bearing (1) by using special tool (B) and wrench.
Special tool
(B): 09923-73210
3. Remove release bearing and release fork.

Installation

NOTE: Before installation, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.





1. Install flywheel (1) to crankshaft and tighten bolts (2) to specification.
Special tool
(A): 09924-17810
"A": Grease 99000-31110
Tightening torque
Flywheel bolt (a): 70 Nm (7.0 kgf-m, 50.5 ft. lbs.)





2. Using special tool (B), install input shaft bearing to flywheel.
Special tool
(B): 09925-98210





3. Aligning clutch disc to flywheel center by using special tool (C), install clutch cover (1) and bolts. Then tighten bolts to specification.

NOTE:
^ While tightening clutch cover bolts, compress clutch disc with special tool (C) by hand so that disc centered.
^ Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924-17810
(C): 09923-36320
Tightening torque
Clutch cover bolt (b): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
4. Install clip (2) to release fork (1) and apply grease.
"A": Grease 99000-25010
5. Install release fork (1) and release bearing as shown in the figure.
6. Slightly apply grease to input shaft (3) and install clutch disc.
"B": Grease 99000-25210





7. Join transmission transfer assembly with engine.

NOTE: Turn crankshaft with wrench from front while inserting transmission input shah (3) to clutch disc until splines mesh.

Inspection
Input Shaft Bearing and Release Bearing
Check bearing for smooth rotation and replace it if abnormality is found.

Clutch Disc





Measure depth of rivet head depression, i.e. distance between rivet head and facing surface. If depression is found to have reached service limit at any of holes, replace disc assembly.
Rivet head depth
Standard: 1.6 mm (0.06 inch)
Service limit: 0.5 mm (0.02 inch)

Clutch Cover
^ Check diaphragm spring for abnormal wear or damage.
^ Inspect pressure plate for wear or heat spots.
If abnormality is found, replace it as assembly. Do not disassemble it into diaphragm and pressure plate.

Flywheel
Check surface contacting clutch disc for abnormal wear or heat spots. Replace or repair as required.