Clutch Replacement

Special Tools Required

Ring gear holder 07LAB-PV00100 or 07924-PD20003
Clutch alignment shaft 07LAF-PT00110
Attachment, 32 x 37 mm 07746-0010200
Driver 07749-0010000
Remover handle 07936-3710100
PRESSURE PLATE REMOVAL AND INSPECTION
1. Remove the transmission.
2. Check the height-variation of the diaphragm spring fingers using the dial indicator (A). If the variation is more than the service limit, replace the pressure plate.
3. Install the ring gear holder (A), the clutch alignment shaft (B), and the remover handle (C).
  
  Fig 2: Installing Special Tools
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B).
5. Remove the release bearing (C) from the pressure plate.
6. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
  
  Fig 3: Inspecting Fingers Of Diaphragm Spring
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Inspect the surface of the pressure plate for wear, cracks, and burning.
8. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate.
  Standard (New): 0.03 mm (0.001 in.) max. Service Limit: 0.15 mm (0.006 in.)
  
  Fig 4: Inspecting Pressure Plate For Warpage
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Check the play of the release bearing by spinning it with your hand, if there is excessive play, replace the release bearing with a new one.
  NOTE: The release bearing is packed with grease. Do not wash it in solvent.
  
  Fig 5: Checking Play Of Release Bearing
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
  
  CLUTCH DISC REMOVAL AND INSPECTION
10. Remove the clutch disc (A), the clutch alignment shaft (B), and the remover handle (C).
  
  Fig 6: Removing Clutch Disc And Special Tools
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. Inspect the lining of the clutch disc for signs of slipping or oil. If the clutch disc looks burnt or is soaked with oil, replace it and the pressure plate as a set. If the clutch disc is oil soaked, find and repair the source of the oil leak.
12. Measure the Standard (New): 8.2-8.9 mm (0.32-0.35 in.) Service Limit: 6.0 mm (0.24 in.) clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc.
  Standard (New): 8.2-8.9 mm (0.32-0.35 in.) Service Limit: 6.0 mm (0.24 in.)
  
  Fig 7: Measuring Clutch Disc Thickness
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
  
  Fig 8: Measuring Rivet Depth From Clutch Disc Lining Surface To Rivets
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
13. Measure the depths of the rivets from the clutch disc lining surface (A) to the rivets (B), on both sides. If the measurement is less than the service limit, replace the clutch disc.
  Standard (New): 1.2-1.7 mm (0.047-0.067 in.) Service Limit: 0.2 mm (0.008 in.)
14. Remove the ring gear holder
15. Inspect the ring gear teeth for wear and damage.
16. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning
17. Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel, and recheck the runout. Resurfacing the flywheel is not recommended.
  Standard (New): 0.05 mm (0.002 in.) max. Service Limit: 0.15 mm (0.006 in.)
  
  Fig 9: Measuring Flywheel Runout
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
18. Turn the inner race of the ball bearing (A) with your finger. The ball bearing should turn smoothly and quietly. Check that the ball bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the ball bearing.
  
  Fig 10: Turning Inner Race Of Ball Bearing
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
  
  FLYWHEEL AND PILOT BEARING REPLACEMENT
19. Install the ring gear holder (A).
  
  Fig 11: Installing Special Tool
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
20. Remove the flywheel mounting bolts (B) in a crisscross pattern in several steps, then remove the flywheel and the ring gear holder.
21. Remove the pilot bearing (A) from the flywheel (B).
  
  Fig 12: Removing Ball Bearing From Flywheel
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
22. Install a new pilot bearing into the flywheel using the 32 x 37 mm bearing driver attachment (A) and the 15 x 135L driver handle (B) as shown. Apply a light coat of engine oil to the bearing surface.
  
  Fig 13: Driving New Ball Bearing Into Flywheel
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
23. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and the mounting bolts, finger-tight.
24. Install the ring gear holder (A), then torque the flywheel mounting bolts in a crisscross pattern in several steps.
  
  Fig 14: Installing Special Tool With Torque Specifications
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
  
  Clutch Disc and Pressure Plate Installation
25. Apply super high temp urea grease (P/N 08798-9002) into the groove (A) of the release bearing (B). Temporary install the release bearing onto the release bearing guide. Make sure the release bearing slides freely on the release bearing guide, and remove extra overflow grease. Then install the release bearing on the pressure plate (C).
  
  Fig 15: Installing Ring Gear Holder
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
26. Install the ring gear holder.
27. Install the clutch disc using the clutch alignment shaft (D) and the remover handle (E
28. Apply super high temp urea grease (P/N 08798-9002) into the groove (A) of the release bearing (B). Temporary install the release bearing onto the release bearing guide. Make sure the release bearing slides freely on the release bearing guide, and remove extra overflow grease. Then install the release bearing on the pressure plate (C).
  
  Fig 16: Installing Release Bearing On Pressure Plate
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
29. Install the pressure plate and the mounting bolts (D), finger-tight. Make sure the release bearing does not come off.
30. Torque the mounting bolts in a crisscross pattern in several steps to prevent warping the diaphragm spring.
  Pressure Plate Mounting Bolt Torque: 25 N.m (2.6 kgf.m, 19 lbf.ft)
31. Remove the ring gear holder, the clutch alignment shaft, and the remover handle.
32. Make sure the diaphragm spring fingers are all the same height.
33. Install the transmission.
  
  Fig 17: Tightening Mounting Bolts To Specified Torque
  Courtesy of AMERICAN HONDA MOTOR CO., INC.