Repair Procedures

REMOVAL

1. To remove the transaxle assembly, first drain the clutch fluid and transaxle gear oil, then remove the air cleaner joint and the mounting bracket etc.
2. Remove the clutch release lever (A).
(1) Loosen the release lever nut and washer.
(2) Remove the clevis pin and snap ring from the release cylinder.
(3) Remove the release lever (A).

NOTE:
- It is impossible to remove the transaxle assembly without performing this step because the clutch cover assembly, release bearing and release fork are held together.
- To reduce rattling noise from the gear, a new dual mass flywheel has been used. Due to the application of the dual mass flywheel, the clutch assembly has also been changed. When replacing the flywheel with the dual mass flywheel, the clutch disc and cover should be replaced with the new parts at the same time.




3. Loosen the bolts attached to the release cylinder and remove the release cylinder.
4. Remove the transaxle assembly, after removing each bolt which connects the transaxle assembly and engine.
5. If the clutch cover is attached to the flywheel, remove the release bearing using snap-ring pliers.




(1) Rotate the release bearing in an easy direction in order to examine the snap ring.
(2) Insert the pliers under the wave washer as shown in the illustration and place it in the center of the snap ring.
(3) Spread the snap ring by pushing down on the bearing as shown in the illustration.




(4) The snap ring (A) at expanded state is shown in the figure.




(5) With the snap ring expanded, pull out the release bearing and remove it.
6. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from shifting.
7. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover.

NOTE:
Do not clean the clutch disc or the release bearing with cleaning solvent.

8. Remove the release fork shaft and bushing.

Installation

1. Apply multipurpose grease to the spline of the disc.

Grease: CASMOLY L 9508


CAUTION:
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease.
It can cause clutch slippage and vibration (shudder).




2. Install the clutch disc assembly to the flywheel using the special tool (09411-25000).
3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star pattern.

Tightening torque
Clutch cover bolt:
15 - 22 Nm (150 - 220 kg-cm, 10 - 16 lb-ft)





4. Align the bearing (A) to the release fork (B) and then install it to the sleeve of the housing.

CAUTION:
Apply multipurpose grease (CASMOLY L9508) to the bearing sleeve and contact point of the release fork.




5. Install the release lever to the release fork.




6. Install the transaxle assembly to the engine.

CAUTION:
If the transaxle assembly is installed to the engine without performing this step, the release bearing can be separated, as the release fork rotates freely.

7. After finishing step 6, push the release lever to the arrow mark. If there is a click sound, the release bearing and clutch cover are aligned correctly. If the assembly does not snap into place, start with step 1 again.
Release lever operating range is 3° or less. If the range is over 3°, the release bearing and clutch cover are not aligned correctly. Push the release lever to the arrow mark one more time.