Service manual

EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been complied to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
9
Bearings
Pitting/Damage→ Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-
moval and disassembly section.
1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.
2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
3. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessary
removal job.
6. For jobs requiring more information, the step-by-step format supplements 6 are given in addition
to the exploded diagram and job instruction chart.
ENG
4-30
Extent of removal Order Part name Q’ty Remarks
CLUTCH PLATE AND
FRICTION PLATE REMOVAL
Preparation for Drain the transmission oil.
Refer to “TRANSMISSION OIL REPLACE-
removal MENT “ section in the CHAPTER 3.
Bolt (brake pedal) Shift the brake pedal downward.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Screw (clutch spring) 5
3 Clutch spring 5
4 Pressure plate 1
5 Push rod 1
6 Plain washer 2
7 Bearing 1
8 Friction plate 8
9 Clutch plate 7
CLUTCH AND PRIMARY DRIVEN GEAR
Extent of removal: 1 Clutch plate and friction plate removal
EC490000
CLUTCH AND PRIMARY DRIVEN GEAR
EC498000
CLUTCH PLATE AND FRICTION PLATE
1
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
ENG
4-32
CLUTCH AND PRIMARY DRIVEN GEAR
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
9
Nut 1
9
Lock washer 2
9
Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4, 5 to hold the clutch boss.
å
For USA and CDN
∫
Except for USA and CDN
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
9
Clutch housing 1
Cracks/Wear/Damage → Replace.
9
Clutch boss 2
Scoring/Wear/Damage → Replace.
EC484201
Primary driven gear
1. Check:
9
Circumferential play
Free play exists → Replace.
9
Gear teeth a
Wear/ Damage → Replace.
EC484400
Clutch spring
1. Measure:
9
Clutch spring free length a
Out of specification → Replace springs as
a set.
Clutch holding tool:
YM-91042................................
44
90890-04086............................
55
Clutch spring free length:
Standard <Limit>
40.1 mm 38.1 mm
(1.579 in) (1.500 in)
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