Clutch: Service and Repair

REMOVAL
1. Remove transmission from engine.
2. Remove clutch cover and disc, as follows:
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.

CLUTCH PARTS INSPECTION





1. Inspect clutch disc for wear or damage. Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 inch).
If necessary, replace the clutch disc.





2. Inspect clutch disc runout . Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 inch).
If necessary, replace the clutch disc.





3. Inspect flywheel runout. Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 inch).
If necessary, replace the flywheel.





4. Inspect pilot bearing. Turn the bearing by hand while applying force in the rotation direction. If the bearing sticks or has much resistance, replace the pilot bearing.

NOTE: The bearing is permanently lubricated and requires no clearing or lubrication.

5. If necessary, replace pilot bearing, as follows:





a. Using Special Service Tool (SST) 09303-35011 or equivalent, remove the pilot bearing.





b. Using SST 09304-30012, install the pilot bearing.

NOTE: After assembling the pilot bearing to the hub. install sure that it rotates smoothly.





6. Inspect diaphragm spring for wear. Using calipers, measure the diaphragm spring for depth and width of wear.
Maximum:
Depth A: 0.6 mm (0.024 inch).
Width B: 5.0 mm (0.197 inch).
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. If necessary, replace the release bearing.

INSTALLATION
1. Install clutch disc and clutch cover on flywheel, as follows:





a. Insert SST 09301-00110 or equivalent, in the clutch disc, and then set them and the clutch cover in position.





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

NOTE: 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 non-alignment: 0.5 mm (0.020 inch)
If alignment is not as specified, using SST 09333-00013 or equivalent, adjust the diaphragm spring tip alignment.
3. Apply molybdenum disulfide lithium base grease (NLGI NO.2), as follows:





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

NOTE: Recommended grease part number 08887- 01706 (100 g).

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.