Page 417 of 3051

SCL729
RemovalNLCL00421. Remove fuel filter mounting bracket.
2. Remove air cleaner and air duct.
3. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
4. Remove flare nut using a flare nut wrench.
5. Remove clutch hose and clutch tube.
SCL730
InstallationNLCL00431. When installing clutch hose to bracket, face lock plate in the
correct direction as shown to secure clutch hose.
CAUTION:
Install clutch hose without twisting or bending it.
2. Tighten flare nut to the specified torque, using a flare nut
wrench.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
CAUTION:
Be careful not to damage flare nut and clutch tube.
3. Install clutch hose to operating cylinder, and tighten mounting
bolts to the specified torque.
: 17 - 19 N´m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)
4. After finishing the operation, bleed air from the clutch piping.
Refer to ªBleeding Procedureº, CL-10.
PIPING
Removal
CL-16
Page 418 of 3051

ComponentsNLCL0044
SCL819
SCL820
RemovalNLCL00451. Remove manual transaxle from vehicle. Refer to MT-18,
ªRemovalº.
2. Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch lever.
3. Support clutch lever claws with an appropriate wood block,
align retaining pin with A in the figure, and drive out spring pin
using a pin punch.
4. Pull out withdrawal lever and remove clutch lever.
SCL733
InspectionNLCL0046+Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.
+Replace the withdrawal lever if its contact surface is worn
abnormally.
+Replace the clutch lever if its contact surface is worn abnor-
mally.
+Replace the dust seal if it is deformed or cracked.
InstallationNLCL0047CAUTION:
+Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.
+Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.
CLUTCH RELEASE MECHANISMRS5F70A
Components
CL-17
Page 419 of 3051

YCL002
+Clean old grease and abrasive materials off the grease
application area.
+Apply approximately 1 mm (0.04 in)-thick clutch sleeve
grease evenly on the sliding part of the clutch lever and
the release bearing spring.
+Apply just enough clutch sleeve grease to fill up the
release bearing inner groove.
+Apply the clutch grease to the clutch disc and the input
shaft spline. Install the clutch disc to the input shaft,
remove the excess grease around the shaft, and remove
the clutch disc.
+Lightly and evenly apply the clutch sleeve grease on the
sliding part of the release bearing, install the release
bearing, remove the excess grease around the bearing,
and remove the release bearing.
SCL822
1. Assemble clutch lever to clutch housing, and insert withdrawal
lever.
2. Support clutch lever claws with an appropriate wood block, and
install a new spring pin using a pin punch.
CAUTION:
Spring pin cannot be reused.
SCL736
3. Install release bearing spring to release bearing as shown in
the figure.
SCL823
4. Operate withdrawal lever manually, press clutch spring from
both sides, and install release bearing to clutch lever securely.
5. Make sure a click is heard when release bearing spring is
pressed from both sides.
CLUTCH RELEASE MECHANISMRS5F70A
Installation (Cont'd)
CL-18
Page 420 of 3051
SCL738
6. Make sure each sliding part operates smoothly when with-
drawal lever is moved.
CAUTION:
Remove any excess grease with a shop towel.
CLUTCH RELEASE MECHANISMRS5F70A
Installation (Cont'd)
CL-19
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ComponentsNLCL0027
SCL842
RemovalNLCL00281. Remove manual transaxle from vehicle. Refer to MT-20,
ªRemovalº.
2. Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch withdrawal lever.
3. Remove dust cover.
4. Remove retainer spring from withdrawal lever.
SCL733
InspectionNLCL0029+Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.
+Replace the withdrawal lever if its contact surface is worn
abnormally.
+Replace the dust cover if it is deformed or cracked.
InstallationNLCL00301. Apply a coat of grease to parts as instructed in the following
cautions and notes before installation.
CAUTION:
+Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.
+Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.
CLUTCH RELEASE MECHANISMRS5F50A
Components
CL-20
Page 422 of 3051
+Clean old grease and abrasive materials off the grease
application area.
SCL815
NOTE:
+Equally apply a coat [approximately 1 mm (0.04 in) thick] of
clutch sleeve grease to withdrawal lever and holder spring
frictional surfaces.
+Apply a coat of clutch sleeve grease to the grooves on contact
surfaces of the withdrawal lever ball pin and inner surface of
release bearing so that grease application, make sure that
grease is flush with grooves.
+Equally apply a thin coat of clutch sleeve grease to release
bearing frictional surface. After grease application, install
release bearing. Wipe off excess grease forced out during
bearing installation. Remove release bearing.
2. Installation is in the reverse order of removal.
CLUTCH RELEASE MECHANISMRS5F50A
Installation (Cont'd)
CL-21
Page 423 of 3051
ComponentsNLCL0031
NCL054
SCL229
Inspection and AdjustmentNLCL0032CLUTCH DISCNLCL0032S01+Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
MODEL 240, MODEL 215 (Part number 30100-
2F205)
0.3 mm (0.012 in)
Wearing thickness of facing:
MODEL 215 (Part number 30100-2F215)
1.3 mm (0.051 in)
SCL221
+Check clutch disc for backlash of spline and runout of facing.
Maximum spline backlash (at outer edge of disc):
MODEL 215 0.9 mm (0.035 in)
MODEL 240 1.0 mm (0.039 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
MODEL 215 102.5 mm (4.04 in)
MODEL 240 115 mm (4.53 in)
+Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Components
CL-22
Page 424 of 3051
SCL466-C
AEM100
NCL055
NCL056
:10 -20 N´ m (1- 2kg-m ,7-14 ft-lb)
:22 -29 N´ m (2.2- 3.0 kg-m ,15 -21 ft-lb)
:35 -44 N´ m (3.5- 4.5 kg-m ,26 -32 ft-lb)
Inspection and Adjustment (Cont'd)