Clutch: Service and Repair

REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE





2. REMOVE CLUTCH COVER AND CLUTCH DISC
a. Place matchmarks 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, CLUTCH RELEASE BEARING AND CLUTCH RELEASE FORK FROM TRANSMISSION
a. Remove the boot and release bearing together with the fork.
b. Remove the clip from the release bearing.

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 necessary, 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 necessary, replace the clutch disc.





3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator with roller instrument, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 inch)
If necessary, replace the flywheel.





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 cleaning 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, make sure that it rotates smoothly.

d. Install and torque 2 new bolts.
Torque: 85 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)
Width B: 5.0 mm (0.197 inch)
If necessary, replace the clutch cover.





7. INSPECT CLUTCH 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, then insert them in the flywheel.
SST 09301-00110

HINT: Take care not to insert the clutch disc in the wrong direction.





b. Align the matchmarks on the clutch cover and flywheel.
c. Following the procedures, tighten the 6 bolts in the order starting from the bolt locating near the knock pin on the top.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)

HINT:
- Following the order, tighten the bolts at a time evenly.
- Shake SST up and down, right and left lightly, after checking that the disc is in the center, tighten the 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 alignment is not as specified value, using SST, adjust the diaphragm spring tip alignment.
SST 09333-00013





3. APPLY RELEASE HUB GREASE
Apply release hub grease to the release fork and hub contact, release fork and push rod contact and release fork pivot points.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent





4. APPLY CLUTCH SPRING GREASE
Apply clutch spline grease to the input shaft spline.
Sealant: Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent
5. INSTALL BOOT, CLUTCH RELEASE BEARING AND CLUTCH RELEASE FORK TO TRANSMISSION
a. Install the clip to the release bearing.
b. Install the boot and release bearing to the release fork, and then install them to the transmission.
6. INSTALL TRANSMISSION TO ENGINE