Flywheel: Service and Repair

Clutch Replacement

Special Tools Required
^ Clutch alignment shaft 07JAF-PM7012A
^ Ring gear holder 07LAB-PV00100 or 07924-PD20003
^ Driver 07749-0010000
^ Bearing remover shaft 07936-KC10500
^ Handle 07936-3710100
^ Attachment, 28 x 30 mm 07946-1870100
^ Slide hammer, 3/8"-16 commercially available

Pressure Plate and Clutch Disc Removal
1. Check the height of the diaphragm spring fingers using the dial indicator (A). If the height is more than the service limit, replace the pressure plate.





2. Install the clutch alignment shaft (A), handle (B), and the ring gear holder (C).





3. To prevent warping, unscrew the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).
4. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.





5. Inspect the pressure plate (A) surface for wear, cracks, and burning.





6. Use a straight edge (A) and feeler gauge (B) to inspect the pressure plate (C) for warpage. Measure across the pressure plate. If the warpage is more than the service limit, replace the pressure plate.





7. Remove the clutch disc (A), the clutch alignment shaft (B), and handle (C).





8. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc looks burnt or is soaked with oil, replace it. Find the source of the oil leak if the clutch disc is soaked.
9. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc.





10. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc.





Pilot Bearing Inspection
1. Turn the inner race of the pilot bearing with your finger. The pilot bearing should turn smoothly and quietly. Check that the pilot bearing outer race fits tightly in the crankshaft. If the race does not turn smoothly, quietly, or fit tight in the crankshaft, replace the pilot bearing.





Pilot Bearing Replacement
1. Remove the pilot bearing (A) using the bearing remover shaft (B) and the slide hammer (C).





2. Install the new pilot bearing (A) into the crankshaft using the driver (B) and the 28 x 30 mm attachment (C). Apply a light coat of oil to the bearing surface.





Flywheel Inspection
1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning.
3. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Resurfacing the flywheel is not recommended.





Flywheel Replacement
1. Install the ring gear holder (A).





2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel and ring gear holder.
3. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
4. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.





Clutch Disc and Pressure Plate Installation
1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
2. Install the ring gear holder (A).





3. Apply super high temp urea grease (P/N 08798-9002) to the splines (B) of the clutch disc (C), then install the clutch disc using the clutch alignment shaft (D), and handle (E).
4. Install the pressure plate (A) and the mounting bolts (B) finger-tight.





5. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring.





6. Remove the clutch alignment tool set and ring gear holder.
7. Make sure the diaphragm spring fingers are all the same height.

Release Bearing Replacement
1. Remove the release fork boot (A) from the clutch housing (B).





2. Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).
3. Check the play of the release bearing by spinning it by your hand. If there is excessive play or noise, replace the release bearing with a new one.

NOTE: The release bearing is packed with grease. Do not wash it in solvent.





4. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release bearing (B), and release bearing guide (C).





5. With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.
6. Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely.
7. Install the release fork boot (D). Make sure the boot seals around the release fork and clutch housing.
8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B), and that the release bearing slides smoothly.