Application	N•m	Lb-Ft	Lb-In
Pressure Plate Bolt	18 - 28	13 - 21	-
Clutch Release Arm Bolt and Nut	10 - 16	7.5 - 12	-
Clutch Cable Nuts	9 - 13	-	80 - 115

	DT-49086 Bushing Remover/Installer
	DT-49087 Bushing Remover
	09924-17810 Fly Wheel Holder
	DT-49085 Bushing Remover/Installer
	09930-30102 Sliding Shaft
	09943-88211 Bushing, Bearing Installer
	DW210-010 Clutch Center Guide

Condition	Probable Cause	Correction
Slipping Clutch	Improper clutch cable adjustment.	Adjust clutch cable.
	Worn or oily contamination on clutch disc surface.	Replace clutch disc.
	Worn or oily contamination on pressure plate, flywheel surface.	Replace pressure plate, flywheel.
	Damaged or weakened diaphragm spring.	Replace pressure plate.
	Rusted clutch cable.	Replace clutch cable.
Dragging Clutch	Improper clutch cable adjustment.	Adjust clutch cable.
	Worn or weakened diaphragm spring.	Replace pressure plate.
	Worn or rusted splines of input shaft or clutch disc.	Replace input shaft or clutch disc.
	Excessively wobbly clutch disc.	Replace clutch disc.
	Worn clutch disc.	Replace clutch disc.
Fails to Release	Bent or damaged clutch disc.	Replace clutch disc.
	Worn or rusted splines of input shaft or clutch disc.	Replace input shaft or clutch disc.
	Improper operation of clutch release shaft.	Replace clutch release shaft.
	Broken or damaged clutch cable.	Replace clutch cable.
Pedal Stays on Floor When Disengaged	Interfered clutch release bearing.	Lubricate and adjust clutch release bearing.
	Weakened diaphragm spring.	Replace pressure plate.
	Broken or damaged clutch cable.	Replace clutch cable.
Clutch Vibration	Clutch facing with oily contamination.	Replace clutch disc.
	Release bearing slides unsmoothly on input shaft bearing retainer.	Lubricate retainer release bearing.
	Wobbly clutch disc or poor facing contact.	Replace clutch disc.
	Loose clutch disc rivets.	Replace clutch disc.
	Weakened clutch disc torsion spring.	Replace clutch disc.
	Distorted pressure plate or flywheel surface.	Replace pressure plate or flywheel.
	Weakened engine mounting or loosened installing bolt or nut.	Retighten or replace mounting.
Clutch Noise	Worn or broken release bearing.	Replace release bearing.
	Worn input shaft bearing.	Replace input shaft bearing.
	Cracked clutch disc.	Replace clutch disc.
	Pressure plate and diaphragm spring rattling.	Replace pressure plate.
	Improper clutch cable adjustment.	Adjust clutch cable.
	Worn clutch cable.	Replace clutch cable.
Grabbing Clutch	Clutch disc facing with oily contamination.	Replace clutch disc.
	Excessively worn on clutch disc facing.	Replace clutch disc.
	Rivet head showing out of facing.	Replace clutch disc.
	Weakened clutch torsion spring.	Replace clutch disc.

Pedal Travel

120 - 130 mm (4.7 - 5.1 in.)

Clearance Between Pedal and Floor just Before Clutch Connection

50 - 60 mm (1.9 - 2.3 in.)

• Excessively worn cable
• Loose cable
• Bent or distorted cable
• Damaged boot
• Worn end

1. Clutch Disc
2. Pressure Plate
3. Release Bearing
4. Release Shaft
5. Release Shaft Bushing (No.1)
6. Release Shaft Bushing (No.2)
7. Release Shaft Seal
8. Release Arm
9. Clutch Cable Bracket
10. Clutch Cable Adjusting Nut
11. Rear Clutch Release Plate
12. Washer
13. Front Clutch Release Plate
14. Clutch Cable
15. Clutch Pedal

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1. Remove the transaxle from the vehicle. Refer to Section 5B2, Five-Speed Manual Transaxle (Y4M HD).



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2. Remove the pressure plate and the clutch disc.
• Fix the fly wheel using the fly wheel holder 09924-17810.
• Remove the pressure plate bolts (1).
• Remove the pressure plate and the clutch disc (2).

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1. Pressure plate inspection .
• Check the weak and damaged diaphragm spring (1).
• Check the polluted face by the oil, grease (2).



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2. Clutch disc inspection.
• Measure rivet head depth from clutch disc surface and replace if below limit.
Unit : mm (in.)

Rivet Head Depth		Standard	Limit
		1.2 (0.047)	0.5 (0.02)

• Replace the clutch disc if clutch disc surface is contaminated or clutch disc rivets are loosen.



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3. Clutch disc runout in rotational direction inspection.
• Measure runout in rotational direction and replace if runout exceeds limit.
Unit : mm (in.)

Disc Runout Limit in Rotational Direction (Periphery)

1.0 (0.039)

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1. Install the pressure plate and the clutch disc.
• Install the clutch disc.
• Install the pressure plate (1).
• Align the pressure plate and the clutch disc onto the flywheel using the clutch center guide DW210-010 and the flywheel holder 09924-17810.
• Install the pressure plate bolts.
Tighten
Tighten the bolts to 18-28 N•m (13-21 lb-ft).




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2. Install the transaxle into the vehicle. Refer to Section 5B2, Five-Speed Manual Transaxle (Y4M HD).

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1. Remove the transaxle from the vehicle. Refer to Section 5B2, Five-Speed Manual Transaxle (Y4M HD).
2. Remove the release arm. Refer to "Clutch Release Arm" in this section.
3. Remove the release bearing.



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4. Remove the release shaft and bushing.
• Remove the bushing (No.2) and seal using the bushing remover/installer DT-49085 and hammer.
• Remove the release shaft.



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• Install the bushing remover/installer DT-49086 and the bushing remover DT-49087 to the bushing (No.1).
• Connect the sliding shaft 09930-30102 to the end of the bushing remover/installer DT-49086.
• Remove the bushing (No.1) by pulling.

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1. Release bearing inspection.
• Check for noisy, worn and damaged release bearing.
• Check for a grabbing rotation of release bearing.
• Replace the release bearing if necessary.



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2. Release shaft inspection.
• Check for a warped shaft (1).
• Check for a worn fork (2).
• Replace the shaft if necessary.

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1. Install the release shaft bushing (No.1) using the bushing remover/installer DT-49086, bushing, bearing installer 09943-88211 and a hammer.



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2. Install the release shaft.
• Coat the release shaft and bushing with grease.
3. Install the release shaft bushing (No.2) and seal using the bushing remover/installer DT-49085 and a hammer.



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4. Install the release bearing.
• Coat the spline of transaxle input shaft with multi-purpose grease.
• Coat the release bearing bore and the connecting of release shaft with multi-purpose grease.
• Install the release bearing.
5. Install the release arm. Refer to "Clutch Release Arm" in this section.
6. Install the transaxle into the vehicle. Refer to Section 5B2, Five-Speed Manual Transaxle (Y4M HD).

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1. Disconnect the negative battery cable.
2. Disconnect the clutch cable.
• Remove the adjusting nut (1).
• Remove the front clutch release plate, the washer and the rear clutch release plate(2).
• Disconnect the cable from the clutch release arm.



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3. Remove the clutch release arm.
• Remove the bolt and nut (1).
• Remove the release arm (2).

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1. Install the clutch release arm.
• Install the clutch release arm matching to punched mark (1).
Tighten
Tighten the bolt and nut to 10-16 N•m (7.5-12 lb-ft).




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2. Connect the clutch cable.
• Connect the cable to the clutch release arm.
• Install the front clutch release plate, the washer and the rear clutch release plate.
• Install the clable adjust nut.
3. Adjust the clutch cable. Refer to "Diagnosis" in this section.
4. Connect the negative battery cable.

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1. Disconnect the negative battery cable.
2. Disconnect the clutch cable from the transaxle.
• Remove the adjusting nut (1).
• Remove the front clutch release plate, the washer and the rear clutch release plate (2).
• Pull and remove the cable from the transaxle mount hole (3).



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3. Disconnect the clutch cable from the pedal.



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4. Remove the clutch cable nuts and the cable.

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1. Install the clutch cable and the cable.
Tighten
Tighten the nuts to 9-13 N•m (80-115 lb-in).




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2. Connect the clutch cable to the pedal.



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3. Connect the clutch cable.
• Install the cable to the transaxle mount hole.
• Install the front clutch release plate, the washer and the rear clutch release plate.
• Install the cable adjust nut.
4. Adjust the clutch cable. Refer to "Diagnosis" in this section.
5. Connect the negative battery cable.

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1. Disconnect the clutch cable. Refer to "Clutch Cable" in this section.
2. Remove the clutch pedal.
• Release the pedal return spring.
• Remove the nut.
• Remove the shaft.
• Remove the clutch pedal.
• Remove the bushings.
• Remove the pedal return spring.

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Notice : Be sure to coat the shaft, the bushings and the spring with grease.
1. Install the pedal return spring.
2. Install the bushings.
3. Install the clutch pedal.
4. Install the shaft.
5. Install the nut.
6. Fix the pedal return spring.
7. Connect the clutch cable.
8. Adjust the clutch cable. Refer to "Diagnosis" in this section.