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Clutch

CLUTCH

NOTE

Clutch

CLUTCH 6-11

Always install a new oil seal when the clutch release shaft is removed.

CAUTION

CAUTION
When inserting the release shaft, be careful not to remove the spring of the oil seal.

• Apply high temperature grease to the oil seal lips in the clutch cover.

• Apply engine oil to the bearings in the hole of the clutch cover.

• Apply engine oil to the release shaft.

• Turning the release lever toward the rear, insert the re­lease shaft straight into the hole of the clutch cover.

• Install the clutch inner cable tip in the release lever.

• Turn the release lever clockwise until it becomes hard to turn.

○The release lever should have proper clearance and an­gle as shown.

1 ∼ 3 mm

80° ∼ 90°

Clutch Removal

• Drain the engine oil (see Engine Oil Change in the Peri­odic Maintenance chapter).

• Remove the clutch cover (see Clutch Cover Removal).

• Remove the clutch spring bolts [A], washers [B] and springs.

• Remove the clutch spring plate [C] with the thrust ball bearing [D] and pusher [E]. Remove the friction plates and steel plates.

• When loosening the clutch hub self-locking nut [A], use the clutch holder [B] to keep the clutch hub from turning as shown.

Special Tool - Clutch Holder: 57001-1243

Remove the clutch hub self-locking nut and washer.

• Pull out the clutch hub [A] and thrust washer [B].

○The clutch housing can not be removed without major disassembly work (see Crankshaft/Transmission chap­ter).

Clutch Installation

• Install the thrust washer and clutch hub.

• Install the washer.

• Discard the used clutch hub self-locking nut, and install a new self-locking nut with the projected side facing out­ward.

• Install the clutch holder to keep the clutch hub from turning and tighten the clutch hub self-locking nut.

Special Tool - Clutch Holder: 57001-1243

Torque - Clutch Hub Nut: 132 N-m (13.5 kgf-m, 98 ft-lb)

• Install the friction plates and steel plates, starting with a friction plate and alternating them.

○The grooves [A] on the friction plate surfaces are cut tan-gentially and radially, install the friction plates so that the grooves run toward the center in the direction of the clutch housing rotation (counterclockwise viewed from the en­gine right side).

If new dry steel plates and friction plates are in­stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.

• Apply engine oil to the thrust ball bearing.

• Apply molybdenum disulfide grease to the rubbing portion of clutch spring plate pusher.

• Tighten the clutch spring bolts.

Torque -Clutch Spring Bolts: 9.3 N·m (0.95 kgf·m, 82 in·lb)

Clutch Plate Wear, Damage Inspection

• Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear.

• If any plates show signs of damage, replace the friction plates and steel plates as a set.

• Measure the thickness of the friction plate [A] at several points.

• If any of the measurements is less than the service limit, replace the friction plate.

Friction Plate Thickness Standard: 2.9 ~ 3.1 mm (0.114 ~ 0.122 in.)

Service Limit: 2.75 mm (0.1082 in.)

Clutch Plate Warp Inspection

• Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp.

• If any plate is warped over the service limit, replace it with a new one.

Friction and Steel Plate Warp Standard: less than 0.2 mm (0.008 in.)

Service Limit: 0.3 mm (0.012 in.)


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