Clutch: Service and Repair

CLUTCH UNIT REMOVAL




1. Remove transaxle from engine. Refer to Manual Transmission.




2. Remove clutch cover and disc.
a. Place match marks 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.
3. Remove release bearing and fork from transaxle.
Remove the release bearing together with the fork and then separate them.

CLUTCH UNIT INSTALLATION




1. Install clutch disc and clutch cover on flywheel.
a. Insert SST 09301 - 00210 in the clutch disc, and then set them.




b. Align the match marks on the clutch cover and flywheel.
c. Torque the bolts on the clutch cover in the order shown.

Torque: 19 Nm (195 kgf/cm, 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 in.)

If alignment is not as specified, using SST 09333 - 00013, adjust the diaphragm spring tip alignment.




3. Apply molybdenum disulfide lithium base grease (NLGI NO.2).
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 (1009).

4. Install release bearing and fork.
Install the bearing to the release fork, and then install them to the transaxle.
5. Install transaxle to engine. Refer to Manual Transmission.