Clutch Lever Adjustment
Proper clutch lever free play is 8 13 mm (0.3 0.5 in.). Lever play increases with cable stretch and friction plate wear, requiring periodic adjustment. When the clutch lever free play is out of specification, first try adjusting it at the clutch lever as follows.
A. Dust Cover
B. Clutch Lever
C. Locknut
D. Adjuster
E. 8 13 mm (0.3 0.5 in.)
If the clutch lever free play cannot be adjusted at the clutch lever, make the adjustment further down the cable as follows
A. Locknut
B. Adjusting Nut
WARNING
Excess clutch cable play could prevent clutch disengagement and cause a crash resulting in serious injury or death. When adjusting the clutch cable, be sure the upper end of the outer cable is fully seated in its fitting so that it doesn’t slip into place later and create excessive cable play.
NOTE
After the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly
A. Slots
B. Clutch Lever
C. Locknut
D. Adjuster
NOTICE
Do not remove the clutch release shaft unless it is absolutely necessary. If the clutch release shaft is removed, the oil seal must be replaced with a new one. Remove the clutch cover and the gasket.
A. Cable Holder
B. Lower End of the Clutch Cable
C. Clutch Release Lever
D. Clutch Cover Bolts
E. Clutch Cover and Gasket
A. Flywheel
B. Flywheel & Pulley Holder (Special Tool: 57001-1605)
Remove the clutch spring bolts, springs and clutch pressure plate.
A. Clutch Spring Bolts and Springs
B. Clutch Pressure Plate
Remove the friction plates and steel plates.
A. Friction Plates
B. Steel Plates
Frictionand Steel Plates Wear/Damage Inspection
Friction Plate Thickness
A. Thickness
B. Friction Plate
Friction and Steel Plate Warp Inspection
Friction and Steel Plate Warp
A. Surface Plate
B. Friction or Steel Plate
C. Thickness Gauge
Friction and Steel Plate Installation
NOTICE
If dry steel plates and friction plates are installed, apply transmission oil to the sur- faces of each plate to avoid clutch plate seizure.
A. Apply molybdenum disulfide grease.
B. Clutch Spring Push Rod and Washer
A. Flywheel
B. Flywheel & Pulley Holder (Special Tool: 57001-1605)
Tighten the clutch spring bolts to the specified torque.
Tightening Torque
Clutch Spring Bolts: 9.3 N-m (0.95 kgfm, 82 in-lb)
Clutch Cover Bolts: 10 N-m (1.0 kgfm, 89 in-lb) Check the clutch release lever position by measuring the position distance between the lever and the cable bracket while pushing the clutch release lever lightly forward.
A. Clutch Release Lever
B. Push forward
C. Cable Bracket
D. Position Distance (Between Lever and Cable Bracket)
Position Distance
Standard 48 58 mm (1.9 2.3 in.)
A. Adjusting Washer
B. Clutch Pressure Plate
Adjusting Washer
Clutch Release Lever Position and Adjusting Washer Selection
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