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0% found this document useful (0 votes)
49 views10 pagesCarry Section 11
Uploaded by
ines.icscsCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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/ 10
W41.
11-2.
11:3,
11-4,
115.
116.
SECTION 11
CLUTCH
CONTENTS
GENERAL DESCRIPTION ......... Ease Ged Aengciad er ee 12
REMOVAL: isis os tas ain sts sats Ses winds Easel wes Beds 11-4
INSPECTION OF COMPONENTS ...... 0.0 0.0cc0cceeeeeeeeeees 115
INGTALEATION so. ssi ivislees cos seach igs ease vita net Ws
MAINTENANCE SERVICES .............00cc0eeceeeeeeeeeees 11-8
RECOMMENDED TORQUE SPECIFICATION ..........0e00000+ 11-10 11-1. GENERAL DESCRIPTION
The clutch is a diaphragm-spring clutch of a dry single disc type. The diaphragm spring is of 2 tapering
finger type, which is @ solid ring in the outer diameter part, with a series of tapering fingers pointing
inward. The disc, carrying four torsional damper rubber, is slidably mounted on the transmission input
shaft with a serration fit.
The clutch cover is secured to the flywheel, and carries the diaphragm spring in such a way that the
peripheral edge of the spring pushes on the pressure plate against the flywheel (with the disc in between),
when the clutch release bearing is held back: This is the engaged condition of the clutch.
Depressing the clutch pedal causes the release bearing to advance and push on the tips of the tapering
fingers of the diaphragm spring. When this happens, the diaphragm spring pulls the pressure plate away
from the flywheel, thereby interrupting the flow of drive from flywheel through clutch disc to trans-
mission input shaft.
Cluxch cover
Cluteh release bearing
Flywheel
i
| Tansiaion |
input tate
\) 9 \
/
Fi
Cranksnatt
‘uteh die
W-2 11-2, REMOVAL
Removal of clutch presupposes that the trans:
mission has been dismounted according to the
method outlined in SECTION 13 TRANS-
MISSION.
Clutch Cover and Disc
Remove 6 bolts securing clutch cover to fly-
wheel, and take off clutch cover and disc.
(A): Special too! (Flywheel holder 09924-17810)
Clutch Release Bearing
Remove clutch release bearing from transmission
input shaft bearing retainer.
Input Shaft End Bearing
Use bearing remover (special tool) for removal
of this bearing.
1. Input shat bearing
(8): Special too! (Bearing remover 09917-58010)
Clutch Release Sheft Bushes
For replacement of bushes, refer to p. 135
of SECTION 13 TRANSMISSION. 11-3. INSPECTION OF COMPONENTS
Clutch Disc Facing Surface Condition
A burnt or glazed (glass-like surface) facing can
be reconditioned by grinding it with No. 120 —
200 sandpaper. If surface is in bad condition
beyond repair, replace whole clutch disc assemb:
ly.
Sandpaper
Clutch Facing Wear
Check wear of facing by measuring depth of
each rivet head depression, i.e, distance between
rivet head and facing surface. If depression is
found to have reached service limit at any of the
holes, replace clutch disc assembly.
iver eas L_Sandard [Service tit
vet hea =
apres 12mm 05 mm
(0.08 in.) (0.02 in.)
Backlash in Disc Serration Fit
Check backlash by turning disc back and forth
as mounted on transmission input shaft. Replace
disc assembly if backlash is noted to exceed
service limit. Backlash here isa circular displace
ment as measured with a dial indicator.
ce limit
(0.8 mm (0.03 in.)
Backlash in serration fit
Clutch Cover
Inspect clutch cover for evidence of diaphragm
spring rivets getting loose. if rivets are loose
or are getting loose, replace cover assembly as
such cover makes rattling noise when clutch
pedal is depressed.
Inspect tips of tapering fingers (to which the
release bearing exerts a push to disengage clutch)
for wear. If tips are worn excessively, replace
cover assembly.
@ Spring wear;
11-5 Flywheel
Replace release bearing if it sticks, rattles or Check its surface contacting clutch disc for any
makes abnormal noise when spun and turned by wear or damage.
hand.
Input Shaft Bearing
Replace input shaft bearing if it sticks, rattles or
makes abnormal noise when spun and turned by
hand.
11-6 11-4. INSTALLATION
Install clutch by reversing removal procedure.
‘Some important steps will be explained below.
Flywheel
1) Tighten bolts to specification.
Tightening torque |_ Nm | kgm loft
for fywheel bolts | ao — 4g [4.0 — 4.5 |20.0-32.6
2. Fiywhee! bolt
3. Input shaft bearing
(A): Special tool (Flywheel holder 09924-17810)
2) Install input shaft end bearing to flywheel
using bearing installer (special tool).
1. Input haft bearing
(C): Special tool (Input shaft bearing installer
(09943-88210 or 09943-88211)
Clutch Disc and Clutch Cover
Using clutch center guide (special tool), install
clutch disc and clutch cover.
Tighten clutch cover bolts to specification using
flywheel holder (special tool).
Tightening torque | Nem | kgm lb-ft
for clutch cover
sila 1-28 18-28 135-200
bolts
When mounting the clutch cover on the flywheel,
do not forget 2 reamer bolts (3 in figure).
1. cluten cover
2. Cluteh cover bolt
3. Reamer bolt
(A): Special too! (Fiywihee! holder 09924-178 10)
(0): Special too! (Clutch center guide 09923-36330)
Clutch Release Bearing
Before installing retainer, epply grease to its
inner surface.
D Grease (SUPER GREASE “A”)
W7 Clutch Release Shaft Fork
Apply grease to end of fork.
- ae
@ Grease (SUPER GREASE “A”)
Clutch Release Arm
Align 2 punch marks when installing clutch
release arm on clutch release shaft,
Punched marks
75-115io-f
‘Apply ora
Clutch Release Shaft Bushes
For reinstallation of bushes, refer to p. 13-5 in
SECTION 13 TRANSMISSION of this manual.
Transmission
For remounting transmission, refer to p. 13-4 in
SECTION 13 TRANSMISSION of this manual
and reverse dismounting procedure.
18
11-5, MAINTENANCE SERVICES
Clutch Pedal Free Travel
1) Depress clutch pedal, stop the moment
clutch resistance is felt, and measure distance
(clutch pedal free travel). Free travel should
be within following specification.
20 — 30 mm
Clutch pedal free travel |G) yy in)
1. Clutch peat
free tavel
2)If free travel is out of specification, adjust it
with clutch cable outer nuts (pedal &
release arm side).
NOTICE:
After adjusting free travel, make sure that
clutch cable end protrudes 1 — 5 mm from joint
nut as shown below.
Clutch cable joint mee
1 5mm (0.04 ~ 0.198 in.) Clutch Cable Lubrication
Apply grease to hook part (1) of clutch cable,
251m
(15-25 kom)
(119-180 be
: 1, teh pedal
2. Clutch cable joint
3, Clutch cable
Clutch Cable Routing
For right-hand side steering vehicle.
Suspension
Tension cod Frame Radiator
bracket
)owe
‘cuten cable
Viewed trom a
Choke cable
Viewed from atrow “¢
11-9 11-6. RECOMMENDED TORQUE SPECIFICATION
Be sure to torque each nut.or bolt, if loosened, to specification given below.
If specified tightening torque for particular bolt or nut is not included here, refer to p. 0-12 of this manual.
ightening torque
Fastening Parts