Service Manual

Clutch Disassembly and Inspection
1. Insert special tool (or transaxle main shaft) in flywheel
pilot bearing hole to keep disk from falling of
f.
2. Loosen clutch cover capscrews (Item 10) in a diago-
nal sequence.
3. Remove capscrews, washers (Item 11) and clutch
cover (Item 12), then pull out the special tool and
remove
clutch disk (Item 13).
Special tool
(or transaxle main shaft
4. Inspect diaphragm spring end of cover for wear and
Figure 33
uneven height. Replace if wear is evident or height differ-
ence exceeds the limit.
Pressure plate
Diaphragm spring
Torsion spring
Height difference 0.5 mm (.020 in.) maximum
5. Check pressure plate surface for wear, cracks and
color change.
6. Check strap plate rivets for looseness and replace
clutch cover assembly if loose.
7. Check clutch disk facing for loose rivets, uneven con-
tact, deterioration due to seizure, adhesion of oil or
grease. Replace clutch disk if damaged.
Figure 34
8. Measure rivet sink and replace clutch disk if out of
specification.
Rivet sink
Clutch disk thickness
standard value 7.8 – 8.6 mm (.307
– .339 in.)
Clutch disk rivet sink 0.3 mm (.012) minimum
9. Check for torsion spring play or damage and replace
clutch disk if necessary.
10. Install clutch disk on transaxle main shaft. Make sure
clutch slides freely on splines of shaft. Check for exces-
Figure 35
sive play in rotating direction.
11. Inspect flywheel pilot bearing (Item 14) for wear or
damage and replace if necessary
. Inspect flywheel sur-
face for scratches and cracks. Clean any oil or rust off
surface with a light abrasive.
Installing Clutch Disk and Cover
1. Apply a coating of grease to clutch disk spline, then
use a brush to rub it in. Wipe of
f any excess grease.
2. Use special tool (or transaxle main shaft) to place
clutch disk on flywheel.
Figure 36
Special tool
(or transaxle main shaft
3. Install clutch cover assembly. Tighten capscrews a
little at a time, working in a diagonal sequence.
Clutch cover capscrew torque 7.0 – 9.0 Nm (5 – 7 ft–lb)
Workman 3000/4000 Series Page 6 – 21 Drive Train
Drive Train