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.,
9Bearings
Pitting/DamageÕReplace.
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 1is provided for removal and disassembly jobs.
2. Numbers 2are 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 4accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. Extent of removal 5is 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 6are given in addition
to the exploded diagram and job instruction chart.
4-30
ENGCLUTCH AND PRIMARY DRIVEN GEAR
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-removalMENT“ 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
Extent of removal:1Clutch plate and friction plate removal
EC490000CLUTCH AND PRIMARY DRIVEN GEAREC498000CLUTCH 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)
4-32
ENGCLUTCH AND PRIMARY DRIVEN GEAREC493000REMOVAL POINTSEC483211Clutch boss1. Remove:
9Nut 1
9Lock washer 2
9Clutch boss 3
NOTE:Straighten the lock washer tab and use the
clutch holding tool 4, 5to hold the clutch boss.
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For USA and CDN
º
Except for USA and CDN
EC494000INSPECTIONEC484100Clutch housing and boss1. Inspect:
9Clutch housing 1
Cracks/Wear/Damage Õ Replace.
9Clutch boss 2
Scoring/Wear/Damage ÕReplace.
EC484201Primary driven gear1. Check:
9Circumferential play
Free play exists ÕReplace.
9Gear teeth a
Wear/ Damage ÕReplace.
EC484400Clutch spring1. Measure:
9Clutch spring free length a
Out of specification ÕReplace springs as
a set.
Clutch holding tool:
YM-91042................................4 4
90890-04086............................5 5
Clutch spring free length:
Standard
40.1 mm 38.1 mm
(1.579 in) (1.500 in)
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