Clutch: Service and Repair

REMOVAL
1. Remove transmission from engine.





2. Remove clutch cover and disc.
a. Place matchmarks on the flywheel and clutch cover.
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 with the clutch disc.

NOTICE: Do not drop the clutch disc.





3. Remove boot, release bearing and fork from transmission.
Remove the boot and release bearing together with the fork and then separate them.

INSTALLATION
1. Install clutch disc and clutch cover on flywheel.





a. Insert Special Service Tool (SST) 09301 - 00110 in the clutch disc, and then set them.





b. Align the matchmarks on the clutch cover and flywheel.
c. Torque the 6 bolts on the clutch cover in the order shown.
Torque: 19 N.m (14 ft. lbs.)

HINT: Temporarily tighten the No.1 and No.2 bolts.





2. Check diaphragm spring tip alignment.
Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum nonalignment: 0.5 mm (0.020 inch)
If the alignment is not as specified, with SST 09333-00013, adjust the diaphragm spring tip alignment.
3. Apply molybdenum disulphide lithium base grease (NLGI NO.2)





a. Apply release hub grease to the these parts.
- Release fork and hub contact point.
- Release fork and push rod contact point.
- Release fork pivot point.





b. Apply clutch spline grease.
- Clutch disc spline.
4. Install boot, release bearing and fork to transmission.
Install the boot and bearing to the release fork, and then install them to the transmission.
5. Install transmission to engine.