Clutch: Service and Repair

REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE





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.

NOTICE: Do not drop the clutch disc.





3. REMOVE BOOT, RELEASE BEARING AND FORK FROM TRANSMISSION
Remove the boot and release bearing together with the fork and then separate them.

INSPECTION





1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.

Minimum rivet depth: 0.3 mm (0.012 inch)

If it is not as specified, replace the clutch disc.





2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.

Maximum runout: 0.8 mm (0.031 inch)

If it is not as specified, replace the clutch disc.





3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.

Maximum runout: 0.1 mm (0.004 inch)

If it is not as specified, replace the clutch disc.





4. INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the rotation direction. If the bearing sticks or has much resistance, replace the pilot bearing.

HINT: The bearing is permanently lubricated and requires no clearing or lubrication.

5. IF NECESSARY, REPLACE PILOT BEARING
a. Remove the 2 bolts at diametrically opposite points.





b. Using SST, remove the pilot bearing.
SST 09303 - 35011





c. Using SST and a hammer, install a new pilot bearing.
SST 09304 - 30012

HINT: After assembling the pilot bearing to the hub, install sure that it rotates smoothly.

d. Install 2 new bolts.

Torque:
3RZ-FE Engine: 27 Nm (270 kgf-cm, 19 ft. lbs.)
5VZ-FE Engine: 15 Nm (850 kgf-cm, 63 ft. lbs.)





6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and width of wear.

Maximum depth: A: 0.6 mm (0.024 inch)
Maximum width: B: 5.0 mm (0.197 inch)

If it is not as specified, replace the clutch cover.





7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.

HINT: The bearing is permanently lubricated and requires no cleaning or lubrication.

If necessary, replace the, release bearing.

INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL





a. Insert SST in the clutch disc, and then set them.
SST 09301 - 00110





b. Align the matchmarks on the clutch cover and flywheel.
c. Torque the 6 bolts on the clutch cover in the order shown.

Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)

HINT: 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 inch)

If the alignment is not as specified, with SST, adjust the diaphragm spring tip alignment.
SST 09333 - 00013
3. APPLY MOLYBDENUM DISULPHIDE 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.

HINT: Recommended grease part number 08887 - 01706 (100 g).

4. INSTALL BOOT, RELEASE BEARING AND FORK TO TRANSMISSION
Install the boot and bearing to the release fork, and then install them to the transmission.
5. INSTALL TRANS161ISSION TO ENGINE