CLUTCH UNIT REMOVAL


  1. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    for R150 manual transmission: Click here

    for R150F/R151F manual transmission: Click here

  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY


    1. Remove the clutch release bearing assembly together with the clutch release fork sub-assembly from the clutch housing.

    2. Remove the clutch release fork sub-assembly from the clutch release bearing assembly.

    3. Remove the release bearing hub clip from the clutch release bearing assembly.

  3. REMOVE RELEASE FORK SUPPORT


    1. Remove the release fork support from the manual transmission unit.

  4. REMOVE CLUTCH COVER ASSEMBLY


    1. A01J3MJE03

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 6 set bolts and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  5. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.

  6. INSPECT INPUT SHAFT FRONT BEARING


    1. A01J4N5E01

      Turn the bearing by hand by applying rotational force.

      If the bearing sticks or has much resistance, replace the input shaft bearing.

      Tech Tips

      The bearing is permanently lubricated and requires no cleaning or lubrication.

  7. REMOVE INPUT SHAFT FRONT BEARING


    1. Remove any 2 diametrically opposite bolts.

    2. A01J54PE01

      Using SST, remove the input shaft bearing.

      SST
      09303-35011

  8. INSPECT CLUTCH DISC ASSEMBLY

    Note

    When replacing the clutch disc assembly, make sure to perform an inspection of the flywheel sub-assembly and clutch cover assembly.


    1. A01J636E05

      Using a vernier caliper, measure the rivet head depth.

      Minimum rivet depth
      0.3 mm (0.0118 in.)

      If the depth is less than the minimum, replace the clutch disc assembly.

    2. A01J60FE01

      Install the clutch disc to the transmission unit.

      Note

      Be careful not to insert the clutch disc facing the wrong direction.

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

      Maximum runout
      0.8 mm (0.0314 in.)

      If the runout is greater than the maximum, replace the clutch disc assembly.

  9. INSPECT CLUTCH COVER ASSEMBLY


    1. A01J5OUE04

      Using a vernier caliper, measure the depth and width of the worn areas of the diaphragm spring.

      Maximum wear
      Measurement Maximum wear
      A (Depth) 0.5 mm (0.0196 in.)
      B (Width) 6.0 mm (0.236 in.)

      If the depth or width is greater than the maximum, replace the clutch cover assembly.

    2. A01J61WE01
      Text in Illustration
      *1 Hair cracks, scratches or discoloration
      *2 Hair cracks, discoloration or excessive wear

      Perform a visual inspection of the clutch cover assembly.


      1. Inspect for hair cracks or scratches extending from the center outwards, or discoloration.

      2. Inspect for hair cracks in a circular pattern, discoloration or excessive wear.

        If there is any damage, replace the clutch cover assembly.

  10. INSPECT FLYWHEEL SUB-ASSEMBLY


    1. A01J4YKE01

      Using a dial indicator, measure the flywheel runout.

      Maximum runout
      0.1 mm (0.00393 in.)

      If the runout is greater than the maximum, replace the flywheel sub-assembly.

    2. A01J625E01
      Text in Illustration
      *1 Hair cracks, scratches or discoloration
      *2 Hair cracks, discoloration or excessive wear

      Perform a visual inspection of the flywheel sub-assembly.


      1. Inspect for hair cracks or scratches extending from the center outwards, or discoloration.

      2. Inspect for hair cracks in a circular pattern, discoloration or excessive wear.

        If there is any damage, replace the flywheel sub-assembly.

  11. INSPECT CLUTCH RELEASE BEARING ASSEMBLY


    1. A01J5F4E01

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

      If the bearing sticks or has much resistance, replace the release bearing.

      Tech Tips

      The bearing is permanently lubricated and requires no cleaning or lubrication.