Clutch Assembly Service

CLUTCH DISC





Check the following items, and replace if necessary.
- Clutch disc, for burns, discoloration, oil or grease leakage
- Clutch disc, for wear of facing

Wear limit of facing surface to rivet head: 0.3 mm (0.012 inch)





- Clutch disc, for backlash of spline and runout of facing

Maximum backlash of spline (at outer edge of disc): 1.0 mm (0.039 inch)
Runout limit: 1.0 mm (0.039 inch)
Distance of runout check point (from hub center): 120 mm (4.72 inch)

CLUTCH COVER AND FLYWHEEL





- Check clutch cover, installed on vehicle, for uneven diaphragm spring toe height.

Uneven limit: 0.5 mm (0.020 inch)

- If out of limit, adjust the height with Tool.

FLYWHEEL INSPECTION





CAUTION: Do not allow any magnetic materials to contact the ring gear teeth.

- Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.
- Check flywheel runout.

Maximum allowable runout: Refer to (Inspection, Cylinder Block).

INSTALLATION





- Apply recommended grease to contact surface of splines.
- Too much lubricant may damage clutch disc facing.
- Insert Tool into clutch disc hub when installing clutch cover and disc.
- Be careful not to allow grease to contaminate clutch facing.
- Tighten bolts in numerical order, in two steps.

First step: 10 - 20 Nm (1.0 - 2.0 kg.m, 7 - 14 ft. lbs.)
Final step: 22 - 29 Nm (2.2 - 3.0 kg.m, 16 - 22 ft. lbs.)