Clutch Release Fork: Service and Repair

Clutch Release System Removal and Installation
Removal
1. Remove release arm by loosening its nut and bolt.
2. Take out release bearing by turning release shaft.
3. Drive out No.2 bush by using special tool and hammer. Release shaft oil seal will also be pushed out.
Special Tool (A): 09922-46010





4. Remove release shaft (1).





5. Pull No.1 bush out by using special tools.
Special Tool
(A): 09925-46010
(B): 09930-30104

Installation
1. Drive in a new No. 1 bush (1) by using special tools and hammer and then apply grease to bush inside.
Special Tool
(A): 09943-88211
(B): 09923-46020
"A": Grease 99000-25010





2. Install release shaft with return spring.
3. Apply grease to No.2 bush (1) inside and press-fit it by using the same special tool as in remove.
"A": Grease 99000-25010
Special Tool (A): 09922-46010
4. Coat grease to release shaft (3) oil seal (2) and then install it till it is flush with case surface. Use special tool for this installation and face seal lip downward (inside).
"A": Grease 99000-25010
Special Tool (B): 09925-98221





5. Caulk seal at A by using caulking (4) tool and hammer.
6. Hook return spring





7. Apply grease to release bearing inside diameter and release shaft arm (2), then set release bearing (1).
"A": Grease 99000-25010
8. Apply small amount of grease to input shaft (3) spline and front end as well.
"B": Grease 99000-25210





9. Set release arm to release shaft aligning their punch marks (1), then tighten nut (2) and hold it.
Tightening torque
Release arm nut (a): 23 Nm (2.3 kgf-cm, 17.0 ft. lbs.)