Overhaul

1. Remove the clutch release fork with clutch release bearing from the transaxle assy.

1. remove the clutch release bearing assy from the clutch release fork.

1. remove the release fork support from the transaxle assy.

1. 1
   Align the matchmarks on the clutch cover assy with the one on the flywheel sub–assy.
2. 2
   loosen each set bolt one turn at a time until spring tension is released.
3. 3
   remove the 6 bolts, and pull off the clutch cover assy.

1. Using vernier calipers, measure the rivet head depth.

   Maximum rivet depth: 0.3 Mm (0.012 In.)

If necessary, replace the clutch disc assy.

2. install the clutch disc assy to the transaxle assy.

3. Using a dial indicator, check the clutch disc assy runout.

   Minimum runout: 0.8 Mm (0.031 In.)

If necessary, replace the clutch disc assy.

1. Using vernier calipers, inspect the diaphragm spring for depth and width of wear.

   Maximum:
   a (depth): 0.5 Mm (0.020 In.) B (width): 6.0 Mm (0.236 In.)

If necessary, replace clutch cover assy.

1. Using a dial indicator, inspect the flywheel sub–assy runout.

   Maximum runout: 0.1 Mm (0.004 In.)

If necessary, replace the flywheel sub–assy.

1. Turn the release bearing by hand while applying force in the axial direction.

1. Insert sst in the clutch disc assy, then insert them in the flywheel sub–assy.

   Sst 09301–00210

1. 1
   Align the matchmarks on the clutch cover assy and flywheel sub–assy.
2. 2
   following the procedures shown in the illustration, tighten the 6 bolts, in the order starting the bolt locating near the knock pin on the top.

   Torque: 19.1 Nvm (195 Kgf·cm, 14 ft·lbf)

• following the order in the illustration, tighten the bolts at a time evenly.
• Move sst up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.

1. Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.

   Maximum non–alignment: 0.5 Mm (0.020 In.)

If alignment is not as specified, using sst, adjust the diaphragm spring tip alignment.

Sst 09333–00013

1. install the release fork support to the transaxle assy.

   Torque: 36.8 Nvm (375 Kgf·cm, 27 ft·lbf)

1. 1
   Apply release hub grease to the release fork and release bearing assy contact, release fork and push rod contact and release fork pivot points.

   Sealant:
   part no. 08887–01806, Release hub grease or equivalent

2. 2
   install the release fork to the release bearing assy.

1. 1
   apply the clutch spline grease to the input shaft spline.

   Sealant: part no. 08887–01706, Clutch spline grease or equivalent

2. 2
   install the bearing to the release fork, and then install them to the transaxle assy.