Clutch: Service and Repair
Clutch Unit:
REMOVAL OF CLUTCH UNIT
1 REMOVE TRANSAXLE WITH MANUAL TRANSMISSION (REFER TO TRANSMISSION REMOVAL)
NOTE: Do not drain the gear oil.
2. REMOVE CLUTCH COVER AND DISC
(a) Loosen each set bolt one turn at a time until spring tension is released.
(b) Remove the set bolts, and pull off the clutch assembly.
3. REMOVE RELEASE BEARING AND HUB
Remove the bearing clip and pull off the release bearing and hub.
4. REMOVE RELEASE FORK, RETURN SPRING AND FORK LEVER
(a) Remove the mounting bolt.
(b) Pull out the release fork lever, and remove the release fork and return spring.
(c) Remove the lever boot.
INSPECTION AND REPAIR OF CLUTCH PARTS
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 in.) If a problem is found, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout. Maximum runout: 0.8 mm (0.031 in.) If runout is excessive, replace the disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout. Maximum runout: 0.2 mm (0.008 in.) If runout is excessive, repair or replace the flywheel.
4. INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the axial direction.
5. IF NECESSARY, REPLACE PILOT BEARING
(a) Using SST, remove the pilot bearing. SST 09303-35011
(b) Using SST, install a new pilot bearing. SST 09304-30012
6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and width of wear. Maximum: Depth 0.6 mm (0.024 in.) Width 5.0 mm (0.197 in.) If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.
NOTE: The bearing is permanently lubricated and requires no cleaning or lubrication.
8. IF NECESSARY, REPLACE RELEASE BEARING
(a) Using a press and SST, press the release bearing from the hub. SST 09315-00010
(b) Using a press and SST, press a new release bearing into the hub. SST 09315-00010
(c) After installing the bearing, check that there is no drag on the bearing when it is turned under pressure.
9. REPLACE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using a socket wrench, drive in a new oil seal. Oil seal depth: 2.2 mm (0.087 in.)
INSTALLATION OF CLUTCH UNIT
1 INSTALL DISC ON FLYWHEEL
Using SST install the clutch on the flywheel. SST 09301-36010
2. INSTALL CLUTCH COVER
Tighten the bolts evenly and gradually. Make several passes around the cover until the cover is snug. Torque the bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N.m)
3 CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a feeler gauge and SST, measure the gap between the spring tips and the tool. SST 09301-00013 Maximum gap: 0.5 mm (0.020 in.) If gap is excessive adjust as follows.
4. IF NECESSARY, ADJUST SPRINGS
Using SST, bend the springs until alignment is correct. SST 09301-00013
5. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2) OR MP GREASE
(a) Apply molybdenum disulphide lithium base grease to the following parts:
- Release fork and hub contact points
- Release fork and fork lever contact points
- Release fork lever and bushings contact points
- Release fork lever and oil seal contact points
- Release bearing hub inside
- Clutch disc spline
(b) Apply MP grease to the front of the release bearing.
INSTALL RELEASE FORK, RETURN SPRING AND FORK LEVER
(a) Install the lever boot.
(b) Put in the release fork lever and install the release fork and return spring.
(c) Install and torque the mounting bolt.
Torque: 750 kg-cm (54 ft-lb, 74 N.m)
7. INSTALL RELEASE BEARING AND HUB
Insert the bearing and hub and install the bearing clip.
8. INSTALL TRANSAXLE WITH MANUAL TRANSMISSION (REFER TO TRANSMISSION INSTALLATION)
9 CHECK AND ADJUST CLUTCH PEDAL (REFER TO CLUTCH PEDAL ADJUSTMENT)