Clutch Clearance Inspection

Special Tools Required

Clutch compressor attachment 07ZAE-PRP0100

Inspect the clutch piston, the discs, the plates, and the end-plate for wear and damage (see CLUTCH INSPECTION ), and inspect the clutch wave-plate phase difference (see CLUTCH WAVE-PLATE PHASE DIFFERENCE INSPECTION ), if necessary.
Install the 1st-hold clutch piston in the 1st clutch piston, and install the 1st/1st-hold clutch piston (A) in the 1st/1st-hold clutch drum (B). Do not install the O-rings on the clutch pistons during inspection.

Fig 1: Identifying 1st/1st-Hold Clutch Piston And 1st/1st-Hold Clutch Drum
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the 1st-hold clutch flat-plate (A), alternately install the clutch discs (B) (3) and the 1st-hold clutch wave-plates (C) (2), then install 1st-hold clutch plate B (D) with the flat side down in the direction shown.

Fig 2: Identifying 1st-Hold Clutch Flat-Plate, Clutch Discs, 1st-Hold Clutch Wave-Plates And Clutch Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the 1st-hold clutch plate B-to-top disc clearance using a feeler gauge (A) while pressing 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.
Clearance between the 1st-hold Clutch Plate B and the Top Disc:

Service Limit: 0.6-1.0 mm (0.024-0.039 in.)

Fig 3: Measuring 1st-Hold Clutch Plate B-To-Top Disc Clearance Using Feeler Gauge
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the clearance is out of standard, replace the 1st-hold clutch plates and the discs as a set, then recheck.
Install the disc spring (A) on 1st-hold clutch plate B in the direction shown. Starting with the 1st clutch wave-plate, alternately install the wave-plates (B) (5) and the discs (C) (5) in the 1st clutch drum (D), then install the clutch end-plate (E) with the flat side down.

Fig 4: Identifying Disc Spring, 1st-Hold Clutch Plate And Clutch End-Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the clutch pistons in the 2nd, 3rd, 4th, and 5th clutch drums. Do not install the O-rings on the clutch pistons during inspection.

Fig 5: Identifying Clutch Pistons And O-Rings
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Starting with the 2nd clutch flat-plate, alternately install the flat-plates (A) (4) and the discs (B) (4) in the 2nd clutch drum (C), and alternately install the wave-plates (D) (3) and the discs (B) (3). Install the clutch end-plate (E) with the flat side down on the top disc.

Fig 6: Identifying 2nd Clutch Drum, Wave-Plates And Discs
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the disc spring (A) in the 3rd clutch drum (B) in the direction shown. Starting with the 3rd clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.

Fig 7: Identifying 3rd Clutch Drum, Wave-Plates And Discs
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the disc spring (A) in the 4th clutch drum (B) in the direction shown. Starting with the 4th clutch flat-plate, alternately install the flat-plates (C) (2) and the discs (D) (2), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.

Fig 8: Identifying 4th Clutch Drum, Wave-Plates And Discs
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the disc spring (A) in the 5th clutch drum (B) in the direction shown. Starting with the 5th clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3), and alternately install the wave-plates (E) (2) and the discs (D) (2). Install the clutch end-plate (F) with the flat side down on the top disc.

Fig 9: Identifying 5th Clutch Drum, Wave-Plates And Discs
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the snap ring using a screwdriver to secure the clutch end-plate.

Fig 10: Installing Snap Ring Using Screwdriver
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Set a dial indicator (A) on the clutch end-plate (B).

Fig 11: Identifying Dial Indicator And Clutch End-Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the end-plate (A).

Fig 12: Identifying Snap Ring And End-Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Press the clutch compressor attachment down with 150-160 N (15-16 kgf, 33-35 lbf) (B) using a force gauge, and read the dial indicator (C).
The dial indicator reads the clearance (D) between the clutch end-plate and the top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
Clearance between the Clutch End-plate and the Top Disc

Service Limit:

1st Clutch: 1.15-1.35 mm (0.045-0.053 in.)

2nd Clutch: 1.05-1.25 mm (0.041-0.049 in.)

3rd Clutch: 0.80-1.00 mm (0.031-0.039 in.)

4th Clutch: 0.75-0.95 mm (0.030-0.037 in.)

5th Clutch: 0.75-0.95 mm (0.030-0.037 in.)

If the clearance is out of the service limit, select a new clutch end-plate from the following table.

Fig 13: Identifying Clearance Between Clutch End-Plate And Top Disc

Courtesy of AMERICAN HONDA MOTOR CO., INC.

1ST CLUTCH END-PLATES

1ST CLUTCH END-PLATES THICKNESS CHART

Mark	Part Number	Thickness
1	22551-RDK-003	3.1 mm (0.122 in.)
2	22552-RDK-003	3.2 mm (0.126 in.)
3	22553-RDK-003	3.3 mm (0.130 in.)
4	22554-RDK-003	3.4 mm (0.134 in.)
5	22555-RDK-003	3.5 mm (0.138 in.)
6	22556-RDK-003	3.6 mm (0.142 in.)
7	22557-RDK-003	3.7 mm (0.146 in.)
8	22558-RDK-003	3.8 mm (0.150 in.)
9	22559-RDK-003	3.9 mm (0.154 in.)

2ND CLUTCH END-PLATES

2ND CLUTCH END-PLATES THICKNESS CHART

Mark	Part Number	Thickness
1	22561-RDK-003	2.1 mm (0.083 in.)
2	22562-RDK-003	2.2 mm (0.087 in.)
3	22563-RDK-003	2.3 mm (0.091 in.)
4	22564-RDK-003	2.4 mm (0.094 in.)
5	22565-RDK-003	2.5 mm (0.098 in.)
6	22566-RDK-003	2.6 mm (0.102 in.)
7	22567-RDK-003	2.7 mm (0.106 in.)
8	22568-RDK-003	2.8 mm (0.110 in.)
9	22569-RDK-003	2.9 mm (0.114 in.)

3RD CLUTCH END-PLATES

3RD CLUTCH END-PLATES THICKNESS CHART

Mark	Part Number	Thickness
1	22591-RJB-E01	2.1 mm (0.083 in.)
2	22592-RJB-E01	2.2 mm (0.087 in.)
3	22593-RJB-E01	2.3 mm (0.091 in.)
4	22594-RJB-E01	2.4 mm (0.094 in.)
5	22595-RJB-E01	2.5 mm (0.098 in.)
6	22596-RJB-E01	2.6 mm (0.102 in.)
7	22597-RJB-E01	2.7 mm (0.106 in.)
8	22598-RJB-E01	2.8 mm (0.110 in.)
9	22599-RJB-E01	2.9 mm (0.114 in.)

4TH CLUTCH END-PLATES

4TH CLUTCH END-PLATES THICKNESS CHART

Mark	Part Number	Thickness
1	22571-RJB-E01	2.1 mm (0.083 in.)
2	22572-RJB-E01	2.2 mm (0.087 in.)
3	22573-RJB-E01	2.3 mm (0.091 in.)
4	22574-RJB-E01	2.4 mm (0.094 in.)
5	22575-RJB-E01	2.5 mm (0.098 in.)
6	22576-RJB-E01	2.6 mm (0.102 in.)
7	22577-RJB-E01	2.7 mm (0.106 in.)
8	22578-RJB-E01	2.8 mm (0.110 in.)
9	22579-RJB-E01	2.9 mm (0.114 in.)

5TH CLUTCH END-PLATES

5TH CLUTCH END-PLATES THICKNESS CHART

Mark	Part Number	Thickness
1	22571-RJB-003	2.1 mm (0.083 in.)
2	22572-RJB-003	2.2 mm (0.087 in.)
3	22573-RJB-003	2.3 mm (0.091 in.)
4	22574-RJB-003	2.4 mm (0.094 in.)
5	22575-RJB-003	2.5 mm (0.098 in.)
6	22576-RJB-003	2.6 mm (0.102 in.)
7	22577-RJB-003	2.7 mm (0.106 in.)
8	22578-RJB-003	2.8 mm (0.110 in.)
9	22579-RJB-003	2.9 mm (0.114 in.)

Install a new clutch end-plate, then recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and the plates.