Clutch cover assembly
1. |
Check the diaphragm spring end for wear and
uneven height. |
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 thickness of the disc when
free.
Limit : 0.3 mm (0.0118
in.)
|

|
3. |
Check for the 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
1. |
Remove the transaxle assembly.(See 'MT' group
- 'Manual Transaxle') |
2. |
Remove the release
bearing. |
3. |
Remove the clutch cover and the disk from the
engine.
•
|
Insert the special tool
(09411-11000) into the spline hole to support the clutch
disk when removing the clutch
cover. |
•
|
Do not use solvent to clean the
clutch disk and the release
bearing. | | |
4. |
Remove the bushing and the release fork
assembly. |
1. |
Grease where is 10mm from the end of the
transaxle's input shaft, before installing the clutch disk and cover
assembly.

|
2. |
Install the clutch disc assembly to the
flywheel using the special tool
(09411-11000). |
3. |
Install the clutch cover assembly to the
flywheel and temporarily tighten the bolts three steps at a time in
a star pattern.
Tightening
torque :
Clutch cover bolt:
25~36 N.m(2.5~3.6 kgf.m, 18~26
lb-ft)
|

|
4. |
Align the bearing (A) to the release fork (B)
and then install it to the sleeve of the housing.
Apply multipurpose grease (CASMOLY
L9508) to the bearing sleeve, contact point of the release
fork (B) and the bushing inner surface (C).
Groove of bearing sleeve :
0.5~1.0g
Contacting part of release fork :
0.3~0.5g
Bushing's neck :
0.8~1.2g
| |

|
5. |
Install the release lever to the release
fork.

|
6. |
Install the transaxle assembly to the
engine.
If the transaxle assembly is installed
to the engine without performing this step, the release
bearing can be separated, as the release fork rotates
freely. | | |