Page 705 of 2890
G2M0236
4) Depress clutch pedal to assure there is no abnormality
in the clutch system.
B2M0633A
3. Release Bearing and Lever
A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring
1(Models without
hill holder only).
2) Remove the two clips
2from clutch release lever3
and remove release bearing6.
CAUTION:
Be careful not to deform clips.
3) Remove release lever seal
4.
B2M0174A
4) Remove release lever retainer spring from release lever
pivot with a screwdriver by accessing it through clutch
housing release lever hole. Then remove release lever.
5
2-10SERVICE PROCEDURE
2. On-Car Service - 3. Release Bearing and Lever
Page 706 of 2890

B2M0173A
B: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent when servicing the clutch.
1) Check the bearing for smooth movement by applying
force in the radial direction.
Radial direction stroke:
FWD; Approx.
1.0 mm (0.039 in)
AWD; Approx.
1.4 mm (0.055 in)
G2M0240
2) Check the bearing for smooth rotation by applying pres-
sure in the thrust direction.
3) Check wear and damage of bearing case surface con-
tacting with lever.
G2M0241
2. RELEASE LEVER
Check lever pivot portion and the point of contact with
release bearing case for wear.
C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the following
points with a light coat of grease.
Inner groove of release bearing
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease contain-
ing molybdenum disulphide.)
6
2-10SERVICE PROCEDURE
3. Release Bearing and Lever
Page 707 of 2890

B2M0633A
1. MECHANICAL APPLICATION TYPE
1) While pushing release lever
3to pivot and twisting it to
both sides, fit retainer spring
5onto the constricted portion
of pivot.
NOTE:
Confirm that retainer spring is securely fitted by observing
it through the main case hole.
2) Install release bearing
6and fasten it with two clips2.
3) Install release lever seal
4.
G2M0235
4) After remounting engine and transmission on body,
make adjustment of the clutch release lever end play.
CAUTION:
Take care not to twist the cable during adjustment.
5) Install release lever return spring (Models without hill
holder only).
NOTE:
Hook up the return spring to right side hole of the release
lever.
G2M0242
4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either clutch cover or clutch
disc.
G2M0243
3) Remove flywheel.
7
2-10SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover
Page 708 of 2890

B2M0633A
1. MECHANICAL APPLICATION TYPE
1) While pushing release lever
3to pivot and twisting it to
both sides, fit retainer spring
5onto the constricted portion
of pivot.
NOTE:
Confirm that retainer spring is securely fitted by observing
it through the main case hole.
2) Install release bearing
6and fasten it with two clips2.
3) Install release lever seal
4.
G2M0235
4) After remounting engine and transmission on body,
make adjustment of the clutch release lever end play.
CAUTION:
Take care not to twist the cable during adjustment.
5) Install release lever return spring (Models without hill
holder only).
NOTE:
Hook up the return spring to right side hole of the release
lever.
G2M0242
4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either clutch cover or clutch
disc.
G2M0243
3) Remove flywheel.
7
2-10SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover
Page 709 of 2890
B2M0328
B: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of facing.
Replace if facings are worn locally or worn down to less
than the specified value.
Depth of rivet head:
Standard value
1.3—1.9 mm (0.051—0.075 in)
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning fluid.
B2M0329A
2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace clutch disc and inspect transmission front oil seal,
transmission case mating surface, engine rear oil seal and
other points for oil leakage.
B2M0330A
4) Deflection on facing
If deflection exceeds the specified value at the outer cir-
cumference of facing, repair or replace.
Limit for deflection:
1.0 mm (0.039 in) at R = 107 mm (4.21 in)
B2M0333A
5) Worn spline, loose rivets and torsion spring failure
Replace defective parts.
8
2-10SERVICE PROCEDURE
4. Clutch Disc and Cover
Page 710 of 2890

G2M0248
2. CLUTCH COVER
Visually check for the following items without
disassembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at center of
diaphragm spring.
G2M0249
3) Damaged or worn disc contact surface of pressure
plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.
G2M0250
3. FLYWHEEL
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent.
1) Damage of facing and ring gear
If defective, replace flywheel.
G2M0251
2) Smoothness of rotation
Rotate ball bearing applying pressure in thrust direction.
If noise or excessive play is noted, replace ball bearing as
follows:
(1) Drive out ball bearing from flywheel.
(2) Press bearing into flywheel until bearing end sur-
face is flush with clutch disc contact surface of flywheel.
Do not press inner race.
ST 899754112 SNAP RING PRESS
9
2-10SERVICE PROCEDURE
4. Clutch Disc and Cover
Page 711 of 2890

B2M0331A
B2M0332A
C: INSTALLATION
1) Install flywheel.
2) Install ST, and tighten the flywheel attaching bolts to the
specified torque.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72±3 N⋅m (7.3±0.3 kg-m, 52.8±2.2 ft-lb)
NOTE:
Tighten flywheel installing bolts gradually. Each bolt should
be tightened to the specified torque in a crisscross fashion.
G2M0253
3) Insert ST into the clutch disc and install them on the
flywheel by inserting the ST end into the pilot bearing.
ST 499747100 CLUTCH DISC GUIDE
G2M0254
4) Install clutch cover on flywheel and tighten bolts to the
specified torque.
NOTE:
When installing the clutch cover on the flywheel, position
the clutch cover so that there is a gap of 120°or more
between“0”marks on the flywheel and clutch cover. (“0”
marks indicate the directions of residual unbalance.)
Note the front and rear of the clutch disc when installing.
Tighten clutch cover installing bolts gradually. Each bolt
should be tightened to the specified torque in a crisscross
fashion.
Tightening torque:
15.7±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
5) Remove ST.
ST 499747100 CLUTCH DISC GUIDE
10
2-10SERVICE PROCEDURE
4. Clutch Disc and Cover
Page 712 of 2890

1. Clutch System
Condition Possible cause and testing Corrective action
1. Clutch slip-
pageIt is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms.
(a) Engine revs up when shifting.
(b) High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does not increase in
proportion to an increase in engine speed.
(c) Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing.
Method of testing: Put the vehicle in stationary condition with parking brake fully applied. Disengage the clutch and
shift the transmission gear into the first. Gradually allow the clutch to engage while gradually increasing the engine
speed. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not
start off and the engine does not stall.
(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f ) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch
drags.As a symptom of this trouble, a harsh scratching noise develops and control becomes quite difficult when shifting
gears. The symptom becomes more apparent when shifting into the first gear. However, because much trouble of the
this sort is due to defective synchronization mechanism, carry out the test as described after.
Method of testing: Refer to DIAGNOSTIC DIAGRAM on page after.
It may be judged as insufficient disengagement of clutch if any noise occurs during this test.
(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc facing Correct or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f ) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or water) Replace.
3. Clutch chat-
ters.Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially
engaged.
(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive disc Replace clutch disc defection.
(e) Warped pressure plate or flywheel Correct or replace.
(f ) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace mounting.
(h) Improper adjustment of pitching stopper Adjustment.
11
2-10DIAGNOSTICS
1. Clutch System