Clutch Cover and Disc Assembly
CLUTCH COVER AND DISC
Components
Disassembly
1. Remove the transaxle.
2. Insert the special tool (09411 - 11000) at the center spline (to prevent the clutch disc from falling).
3. Diagonally loosen bolts which attach clutch cover to flywheel. Back off bolts in succession, one or two turns at a time, to avoid bending cover flange.
CAUTION: Do not clean the clutch disc or release bearing with cleaning solvent.
Clutch Cover Assembly Inspection
1. Check the diaphragm spring end for wear and uneven height.
2. Replace if wear is evident or height difference exceeds the limit.
Limit:
Diaphragm spring end 0.5 mm (0.02 inch)
3. Check the pressure plate surface for wear, cracks and color change.
4. Check the cover plate rivets for looseness and replace the clutch cover assembly if loose.
Clutch Disc Inspection
1. Check the facing for loose rivets, uneven contact, deterioration due to seizure, and adhesion of oil or grease. Replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification.
Limit:
Rivet sink 0.3 mm (0.012 inch)
3. Check for torsion spring play and damage. Replace the clutch disc if defective.
4. Combine the clutch disc with the input shaft, check sliding condition and check for play in the rotating direction. If it does not slide smoothly, check after cleaning and reassembling. If the play is excessive, replace the clutch disc and/or the input shaft.
Clutch Release Bearing Inspection
1. Because the release bearing is packed with grease, do not use cleaning oil, etc. to clean it.
2. Check for bearing heat damage, other damage, abnormal noise and/or rotation. Also check whether or not there is wear at the point of contact with the diaphragm spring.
3. If there is abnormal wear at the point of contact with the release fork, replace the bearing.
Release Fork Inspection
If there is abnormal wear at the point of contact with the bearing, replace the release fork.
Reassembly
1. Apply a coating of the specified grease to the point of contact with the fulcrum and the point of contact with the release bearing.
Specified grease MOLYWHITE TA No. 2
CAUTION:
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; excessive grease will cause clutch slippage and shudder.
2. Apply a coating of the specified grease to the end of the release cylinder's push rod and to the push rod hole in the release fork.
Specified grease MOLYWHITE TA No. 2
3. Pack the inner surface of the clutch release bearing and the groove with the specified grease.
Specified grease MOLYWHITE TA No. 2
4. Apply a coating of the specified grease to the clutch disc spline, then use a brush to rub it in.
Specified grease MOLYWHITE TA No. 2
5. Using the special tool (clutch disc guide), position the clutch disc to the flywheel.
6. Install the clutch cover assembly. Tighten the bolts a little at a time, working in a diagonal sequence, finally tightening them to the specified torque.
7. Before installing the transaxle assembly, apply a coating of the specified grease to the input shaft spline, then rub it in with a brush.
Specified grease MOLYWHITE TA No. 2