1. |
Drain the clutch fluid and transaxle gear
oil. |
2. |
Remove the transaxle
assembly. |
3. |
Insert the special tool (09411-25000) in the
clutch disc to prevent the disc from
falling. |
4. |
Loosen the bolts that attach the clutch cover
to the flywheel in a star pattern. |
5. |
Loosen the bolts in succession, one or two
turns at a time, to avoid bending the cover flange.
DO NOT clean the clutch disc or release
bearing with cleaning solvent.

| |
1. |
Apply multipurpose grease to the release
bearing contact surfaces and the release cylinder contact surface of
the clutch release fork assembly.
When installing the clutch, apply grease
to each part, but be careful not to apply excessive grease. It
can cause clutchslippage and judder.

| |
2. |
Apply multipurpose grease into the groove of
the release bearing.

|
3. |
Apply multipurpose grease to the 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 to
the clutch disc splines and input shaft splines.
Do not apply more grease than necessary.
Too much grease could cause clutch slip or
judder. | |
6. |
Using the special tool (09411-25000), install
the clutch disc to the flywheel. When installing the clutch disc, be
sure that the surface having the manufactures stamp is towards the
pressure plate side. |
7. |
Install the the clutch cover assembly onto the
flywheel and install the six (6) bolts through the clutch cover into
the flywheel. |
8. |
Tighten the bolts by one or two turns at a
time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten
the bolt temporarily and then torque to specification in diagonal
torquing sequence indicated below.

TIGHTENING
TORQUE Single mass
flywheel: 15~22 N•m (150~220
kgf•cm, 11~16 lbf•ft) Dual mass
flywheel: 20~27 N•m (200~270
kgf•cm, 14~19
lbf•ft)
|
|
9. |
Remove the special
tool. |
10. |
Install the transaxle. (Refer to GROUP -
Manual Transaxle Assembly) |
11. |
Adjust the clutch pedal free-play. (See
CH-6)

|
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.
|
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 clutch 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

|
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
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 |