Clutch Cover and Disc Assembly

REMOVAL
1. Drain the clutch fluid and transaxle gear oil.
2. Remove the transaxle assembly.





3. Insert special tool (09411-11000) or equivalent in the clutch disc to prevent the disc from falling.
4. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

CAUTION: Do not clean the clutch disc or release bearing with cleaning solvent.

INSPECTION
Clutch Cover Assembly
1. Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit of 0.5 mm (0.012 inch).
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.

Clutch Disc
1. Check the facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil or grease and replace the clutch disc if defective.





2. Measure the rivet sink and replace the clutch disc if it is out of specification.
Limit: 0.3 mm (0.012 inch).
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc. If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.

Clutch Release Bearing

CAUTION: The release bearing is packed with grease. Do not use cleaning solvent or oil.

1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.

Clutch Release Fork
1. If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly.

INSTALLATION





1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.

CAUTION: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; It can cause clutch slippage and judder.





2. Apply multipurpose grease, MOLYWHITE TA No. 2 into the groove of the release bearing.





3. Apply multipurpose grease, MOLYWHITE TA No. 2 to clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease, MOLYWHITE TA No. 2 to the clutch disc splines and input shaft splines.

CAUTION: Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.





6. Using special tool (09411-11000) or equivalent, install clutch disc to flywheel. When installing the clutch disc, be sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the cloth cover assembly onto the flywheel and install six (6) bolts through the clutch cover into the flywheel.
8. Diagonally tighten the bolts 15-22 Nm (11-15 ft. lbs.). Tighten the bolts, one or two turns at a time, in succession, to avoid bending the cover flange.
9. Remove the special tool.
10. Install the transaxle.
11. Adjust the clutch pedal free-play.