Clutch Replacement

TOOL REQUIRED
- 07JAF-PM7011A Clutch Alignment Disc
- 07JAF-PM7012A Clutch Alignment Shaft
- 07936-3710100 Handle
- 07LAB-PV00100 Ring Gear Holder
- Or Equivalent

PRESSURE PLATE REMOVAL
1. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area.





2. Check the diaphragm spring fingers for height using the special tools and a feeler gauge. Standard (New): 0.6 mm (0.02 inch) max. Service Limit 1.0 mm (0.04 inch). If the height exceeds the service limit, replace the pressure plate.





3. Install the special tools.
4. To prevent warping, unscrew the pressure plate mounting bolts in a crisscross pattern in several steps, then remove the pressure plate.
5. Inspect the pressure plate surface for wear, cracks, and burning.





6. Inspect for warpage using a straight edge and feeler gauge.

NOTE: Measure across the pressure plate at three points. Standard (New): 0.03 mm (0.001 inch) max. Service Limit: 0.15 mm (0.006 inch). If the warpage exceeds the service limit, replace the pressure plate.

CLUTCH DISC REMOVAL





1. Remove the clutch disc and special tools.
2. Inspect lining of the clutch disc for signs of slipping or oil. If it is burned black or oil soaked, replace it.





3. Measure the clutch disc thickness. Clutch Disc Thickness:
- Standard (New): 8.5 - 9.1 mm (0.33 - 0.36 inch)
- Service Limit: 5.5 mm (0.22 inch)

NOTE: If the thickness is less than the service limit, replace the clutch disc.





4. Measure the depth from the lining surface to the rivets, on both sides. Rivet Depth:
- Standard (New): 1.3 - 1.9 mm (0.05 - 0.07 inch) min.
- Service Limit: 0.2 mm (0.01 inch)

NOTE: If the depth is less than the service limit, replace the clutch disc.

INSTALLATION





1. Install the special tool.
2. Install the clutch disc using the special tools.





3. Install the pressure plate.





4. Torque the mounting bolts in a crisscross pattern as shown. Tighten them in several steps to prevent warping the diaphragm spring.