1 INDEX

Models FA and FB CLUTCH 5-1

5-54E-10

CHAPTER 5 5
CLUTCH
Models FA and FB

TROUBLESHOOTING .................................................................5 - 2

SPECIAL TOOLS ........................................................................5 - 4

REMOVAL ...................................................................................5 - 5

CLUTCH UNIT .............................................................................5 - 6

CLUTCH HOUSING .....................................................................5 - 10

INSTALLATION ...........................................................................5 - 15
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5-2 CLUTCH Models FA and FB

TROUBLESHOOTING

Symptom Possible cause Remedy

Clutch dragging Clutch disc distorted or warped ..................... Replace clutch disc
Transmission input shaft worn ...................... Replace input shaft and check clutch
hub for excessive wear
If worn, replace disc
Check flywheel housing alignment
Excessive clutch control ................................ Replace control parts
parts wear
Clutch control parts not ................................. Replace control parts
functioning properly
Improper clutch control ................................. Adjust clutch control
adjustment
Clutch disc assembly too thick ...................... Replace clutch disc

Clutch slipping Release lever and release bearing ............... Adjust clearance
clearance incorrectly adjusted
Clutch disc facing gummed with ................... Replace disc assembly
oil or grease
Release bearing worn ................................... Replace bearing
Clutch pedal free-play incorrectly .................. Adjust free-play
adjusted
Compression spring weak ............................. Replace cover assembly
Clutch facing worn ........................................ Replace facing or disc assembly
Failing to remove plate from ......................... Remove plate
the clutch pressure plate assembly
Driver riding clutch pedal .............................. Do not ride on the clutch pedal

Vehicle vibrates when Improper engine idling .................................. Adjust idling

starting
Clutch control incorrectly adjusted ................ Adjust clutch control
Clutch disc facing gummed with ................... Replace disc assembly
oil or grease
Glazed flywheel friction surface .................... Deglaze flywheel surface with coarse
emery cloth, stroking parallel to
machining lines
Clutch disc distorted or warped ..................... Replace disc
Improper clutch cover tightening ................... Tighten bolts
Flywheel housing misalignment .................... Replace flywheel housing
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Models FA and FB CLUTCH 5-3

Symptom Possible cause Remedy

Abnormal noise in Malfunction of engine .................................... Tune up engine

transmission
Improper clutch disc used ............................. Replace proper clutch disc
Trouble in transmission ................................. Check transmission
The engine idle speed is low ......................... Increase the idle speed

Noisy clutch Release bearing worn or dry ......................... Replace release bearing
Pilot bearing worn or dry ............................... Replace pilot bearing
Clutch disc distorted or warped ..................... Replace clutch disc
Flywheel housing misalignment .................... Replace flywheel housing
Transmission input shaft or clutch ................. Clean and lubricate or replace
disc spline worn
Insufficient lubrication of pedal and ............... Lubricate
its accessories
Insufficient lubrication of release ................... Lubricate
shaft and release bearing hub
Transmission input shaft retainer .................. Clean or replace if rusted
rusted or soiled
Clutch pedal free-play incorrectly .................. Adjust free-play
adjusted

Clutch pedal can not Clutch control incorrectly adjusted ................ Adjust clutch control
be depressed
Insufficient lubricant release shaft ................. Lubricate
and release bearing hub

Change in clutch Air trapped in clutch fluid ............................... Bleed air

pedal give
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5-4 CLUTCH Models FA and FB

SPECIAL TOOLS
Prior to starting a clutch overhaul, it is necessary to have the following special tools.

Illustration Tool No. Tool name

09650 - 1970 CLUTCH PILOT BEARING PULLER

09420 - 1442 SLIDING HAMMER

09662 - 1200 CLUTCH ALIGNING ARBOR

09654 - 1430 PLATE

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Models FA and FB CLUTCH 5-5

REMOVAL

WARNING
Do not work on the transmission while it is still hot.
This can result in personal injury.

1. BLOCK THE WHEELS.

1. Park the vehicle on level ground.
2. Block the wheels.

NOTE: Be sure to apply wheel stoppers in the front

tires.

SMAT-040
Fig. 1
2. REMOVE THE TRANSMISSION.
NOTE: ● To remove the transmission from the ve-
hicle, refer to CHAPTER 7: TRANSMIS-
SION.
● As the transmission is being removed, sup-
port the weight of the transmission and
keep transmission in alignment with the
engine until the main drive gear (input shaft)
SM7-184 splines clear the clutch assembly. Failure
Fig. 2 to do so could cause distortion or hub
breakage in the driven disc.
3. REMOVE THE CLUTCH COVER ASSEMBLY AND
SPECIAL TOOL
CLUTCH DISC.
1. Insert the special tool (plate) between the clutch
cover and the release lever.
Special Tool: Plate (09654 - 1430)
2. Remove the clutch cover assembly fitting bolts in the
numerical order shown.
3. Remove the clutch cover assembly and clutch disc
from flywheel.

WARNING
The clutch cover assembly and clutch disc are
heavy, be careful not to drop them.

SM5-069A
Fig. 3
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5-6 CLUTCH Models FA and FB

CLUTCH UNIT

1 2

1. Pilot bearing 4. Bolt

2. Clutch disc 5. Pin
3. Clutch cover assembly 6. Clutch housing

Fig. 4
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Models FA and FB CLUTCH 5-7

INSPECTION AND REPLACEMENT

1. INSPECT THE CLUTCH DISC.
1. Check the damper springs for breakage or play.
If any breakage or play is detected, replace the clutch
disc assembly.

SM5-049A
Fig. 5
2. Check the clutch disc for cracks and loose stopper
pin.
If any of these conditions is present, replace the
clutch disc assembly.

SM5-050A
Fig. 6
3. Using a feeler gauge, measure the clearance be-
CLUTCH DISC tween clutch disc and transmission input shaft spline.
CLEARANCE If the clearance is greater than service limit, replace
the clutch disc or input shaft.
Assembly Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in.)
INPUT
SHAFT
Service Limit: 0.5 mm (0.020 in.)

Fig. 7
4. Using a dial gauge, measure the clutch disc runout.
If the runout is greater than service limit, replace the
clutch disc assembly.
Assembly Standard: 0 - 0.38 mm (0 - 0.0149 in.)
Service Limit: More than 0.38 mm (0.0149 in.)

Fig. 8
5. Using a vernier caliper, measure the facing thickness.
If the thickness is less than service limit, replace the
clutch disc assembly.

Facing thickness
Standard: 10.16 mm (0.40 in.)
Service limit: 7.62 mm (0.30 in.)

SM5-051B
Fig. 9
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5-8 CLUTCH Models FA and FB

2. INSPECT THE PRESSURE PLATE.

1. Using a straight edge and a feeler gauge, check the
face runout of the pressure plate.
If the runout is greater than the repair limit, replace
the clutch cover assembly.
Standard: 0 - 0.102 mm (0 - 0.0040 in.)
Repair Limit: 0.76 mm (0.029 in.)

SM5-038
Fig. 10
2. Check the friction surface for scoring or heat crack-
ing.
If necessary, replace the clutch cover assembly.
NOTE: Regrinding of the pressure plate is not pos-
sible.

SM5-038A
Fig. 11
3. INSPECT THE FLYWHEEL.
1. Check the friction surface for scoring or heat crack-
ing.
If necessary, grind the friction surface or replace the
flywheel.
Grind limit: 1 mm (0.039 in)
Deflection limit: 0.04 mm (0.00157 in.)
NOTE: Do not grind the flywheel over than the limit.

Fig. 12
2. Using a straight edge and a feeler gauge, check the
friction surface ware.
If the wear is greater than the sevice limit, replace
the flywheel.
Standard: 0.05 mm (0.0020 in.) or less
Service limit: 1.0 mm (0.039 in.)

Fig. 13
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Models FA and FB CLUTCH 5-9

4. INSPECT THE FLYWHEEL HOUSING.

Using a dial gauge, measure the face runout of fly-
wheel housing relative to the flywheel.
a. Install the dial gauge on the flywheel.
Position the dial gauge so that the gauge button con-
tacts a circumference just outside the flywheel hous-
ing.
b. Push the crank shaft rearward to remove any end
ASM5-002 play.
Fig. 14
c. Set the dial gauge to zero.
d. Holding the crankshaft in the rearward position, ro-
tate the crankshaft through one complete revolution
by using a screw driver on the flywheel ring gear.
e. During rotation, read the maximum value.
If the runout is greater than service limit, replace the
flywheel housing.
Service Limit: 0.2 mm (0.008 in.)

5. INSPECT THE PILOT BEARING (BALL BEARING).

1. Check the pilot bearing for improper rotation.
If necessary, replace the bearing.

SM7-078
Fig. 15
2. Replace the pilot bearing.
a Using special tools, pull out the pilot bearing.
Special Tools:
Clutch pilot bearing puller (09650 - 1970)
Sliding hammer (09420 - 1442)

SM5-056
Fig. 16
b. Install the pilot bearing in the flywheel.

SM5-056
Fig. 17
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5-10 CLUTCH Models FA and FB

CLUTCH HOUSING

5
1
2
3

11

10

12
4
9

7
8

1. Release bearing 7. Release shaft

2. Release bearing hub 8. Clutch housing
3. Grease hose 9. Release shaft bearing
4. Release fork 10. Clutch housing cover
5. Release fork antirattle spring 11. Lubrication fitting
6. Key 12. Gasket

Fig. 18
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Models FA and FB CLUTCH 5-11

DISASSEMBLY OF CLUTCH HOUSING

1. REMOVE THE RELEASE SLEEVE WITH RELEASE
BEARING FROM TRANSMISSION.
1. Remove the antirattle springs.

SM5-082
Fig. 19
2. Disconnect the lubricating hose from the clutch hous-
ing.
3. Remove the release sleeve with bearing.

SM5-083
Fig. 20
2. REMOVE THE CLUTCH HOUSING FROM TRANSMIS-
SION.
1. Remove the clutch housing fitting bolts.
2. Remove the clutch housing.

SM5-084A
Fig. 21
3. REMOVE THE RELEASE SHAFT AND FORK.
1. Remove the release fork lock bolt.

SM5-085B
Fig. 22
2. Slide the release fork and remove the key from the
release shaft.

SM5-086B
Fig. 23
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5-12 CLUTCH Models FA and FB

3. Remove the release shaft and release fork from the

clutch housing.

SM5-087B
Fig. 24

INSPECTION AND REPLACEMENT

1. INSPECT AND REPLACE THE RELEASE BEARING.
1. Check the release bearing for improper rotation by
rotating the outer race.
If necessary, replace the bearing.
NOTE: Do not wash the release bearing.

SM5-088
Fig. 25
2. Replace the release bearing.
a. Using a press, remove the release bearing.
b. Using a press, install the release bearing.
NOTE: ● In order to prevent damage to the race
surface use a pressure for quiet press fit-
ting and do not apply impact loads.
● The load for press fitting should not ex-
ceed 900 kg (1,984 Ib.).
SM6-115A SM6-115B
Fig. 26
2. INSPECT AND REPLACE THE RELEASE SHAFT AND
BEARING.
1. Check the release shaft and bearing for wear and
damage.
If necessary, replace the release shaft and/or bear-
ing.

SM6-132

Fig. 27

RED OIL SEAL AND

2. Using a tapping rod and hammer, remove the bear-
ENGRAVED MARK ing.
3. Install the bearing.
NOTE: The release shaft bearing must be installed
with red oil seal and engraved mark facing
outward.

SM5-090 SM5-014
Fig. 28
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Models FA and FB CLUTCH 5-13

3. INSPECT THE RELEASE FORK.

1. Check the release fork for wear and damage.
If necessary, replace the parts.

SM6-129C
Fig. 29

ASSEMBLY OF CLUTCH HOUSING

1. INSTALL THE RELEASE SHAFT AND RELEASE FORK.
1. Insert the release shaft into the flywheel housing.
When inserting, insert the release fork onto the re-
lease shaft.

SM5-087B
Fig. 30
2. Install the key on the shaft.
3. Slide the release fork on the key and then align the
release fork hole with the release shaft hole.

SM5-091B
Fig. 31
4. Tighten the lock bolt.
Tightening Torque: 140 - 180 kg·cm (11 - 13 lb·ft)

SM5-092B
Fig. 32
2. INSTALL THE CLUTCH HOUSING IN THE TRANSMIS-
SION CASE.
Install the fitting bolts and tighten them.
Tightening Torque: 2,500 - 3,300 kg·cm (181 - 238 lb·ft)

SM5-093A
Fig. 33
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5-14 CLUTCH Models FA and FB

3. INSTALL THE RELEASE SLEEVE WITH RELEASE

BEARING IN THE TRANSMISSION.
1. Install the release sleeve with release bearing.
NOTE: Coat the release sleeve and contact surface
of the front bearing retainer with bearing
grease.
2. Install the antirattle springs.
3. Connect the lubricating hose to the clutch housing.
SM5-083
Fig. 34
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Models FA and FB CLUTCH 5-15

INSTALLATION

1. INSTALL THE CLUTCH DISC.

Insert a clutch disc aligning arbor or splined input
shaft through clutch disc hub and into flywheel pilot
bearing to position clutch disc.
Special Tool: Clutch aligning arbor (09662 - 1200)
NOTE: Apply thin coat of heat-resistance grease
(shell variant-S or equivalent) to the spline
part of the clutch disc and execute centering
SM5-052A with the special tool. (The spline boss pro-
Fig. 35 jection amount from the plate is larger on the
pressure plate side.)
Grease: Refer to RECOMMENDE LUBRICANTS LIST.

2. INSTALL THE CLUTCH COVER ASSEMBLY.

1. Install the clutch cover on flywheel.
NOTE: Be sure to insert the flywheel straight pins
into each place of clutch cover.

SM5-094A
Fig. 36
2. Tighten clutch cover fitting bolts evenly around fly-
wheel.
Tightening Torque: 190 - 260 kg·cm (14 - 18 lb·ft)

Tightening order, see figure 37.

Clutch assembly parts number

Clutch cover : 102101-1
Clutch disc : 103470

NOTE: Use only the clutch cover and clutch disc

cited above. Use of any other parts can lead
to transmission failure.

SM5-095A
Fig. 37
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5-16 CLUTCH Models FA and FB

3. REMOVE THE SPECIAL TOOLS.

SPECIAL TOOL 1. Remove the special tool (plate) between the clutch
cover and the release lever.
2. Remove the alignment tool from clutch disc.
NOTE: When installing the new clutch cover assem-
bly, do not forget to remove the plate from
clutch cover.

Fig. 38
4. APPLY THE HEAT-RESISTANT GREASE ON THE IN-
PUT SHAFT SPLINE AND CLUTCH DISC HUB SPLINE.

Grease: Refer to RECOMMENDED LUBRICANTS

LIST.

SM7-314
Fig. 39
5. INSTALL THE TRANSMISSION.
NOTE: ● To install the transmission in the vehicle,
refer to CHAPTER 7: TRANSMISSION.
● Reinstall transmission. Align transmis-
sion with engine and move it forward to
enter driven disc hub. It may be necessary
to rotate transmission input shaft slightly
to align the splines.
SM7-184 ● Do not leave transmission unsupported
Fig. 40 until it is completely bolted to flywheel
housing, as this practice will distort or
break the driven disc hubs.

6. CHECK THE CLUTCH PEDAL PLAY.

1. Depress the clutch pedal and measure the distance
of the pedal play before the resistance is felt.
Standard: 50 - 65 mm (1.97 - 2.55 in.)
Service Limit: 30 mm (1.18 in.)
2. If the pedal play is less than 30 mm (1.18 in.), adjust
the clutch control system, refer to CHAPTER 6:
CLUTCH PEDAL PLAY CLUTCH CONTROL.
SM5-128
Fig. 41