Engine Side

Pressure Plate Inspection and Removal 

1. Remove the transmission (see TRANSMISSION REMOVAL ).
2. Check the evenness of the height of the diaphragm spring fingers using the clutch alignment disc (A), the clutch alignment shaft (B), the remover handle (C), and a feeler gauge (D). If the height difference is more than the service limit, replace the pressure plate.

   Standard (New): 0.6 mm (0.02 in) max. 

   Service Limit: 0.8 mm (0.03 in) 

   Fig 1: Checking Evenness Of Height Of Diaphragm Spring Fingers Using Clutch Alignment Disc

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Install the ring gear holder (A), the clutch alignment tool set (B), and the 20 mm clutch alignment pilot (C).
   Fig 2: Identifying Ring Gear Holder, Clutch Alignment Tool Set And Clutch Alignment Pilot

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. To prevent warping, loosen the pressure plate mounting bolts (D) in a crisscross pattern in several steps, then remove the pressure plate (E).
5. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.
   Fig 3: Identifying Diaphragm Spring

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. Inspect the pressure plate surface (A) for wear, cracks, and burning.
   Fig 4: Identifying Pressure Plate Surface

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Inspect for warpage using a straight edge (A) and a feeler gauge (B). Measure across the pressure plate (C). If the most measurement difference is more than the service limit, replace the pressure plate.

   Standard (New): 0.02 mm (0.001 in) max. 

   Service Limit: 0.15 mm (0.006 in) 

   Fig 5: Inspecting Warpage Using Straight Edge And Feeler Gauge

   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Clutch Disc Inspection and Removal 

8. Remove the clutch disc (A), the clutch alignment tool set (B), and the 20 mm clutch alignment pilot (C).
   Fig 6: Identifying Clutch Disc, Clutch Alignment Tool Set And Clutch Alignment Pilot

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is oil soaked, replace the clutch disc. If the clutch disc is oil soaked, find and repair the source of the oil leak.
10. Measure the clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc.

    Standard (New): 7.9 - 8.5 mm (0.31 - 0.33 in) 

    Service Limit: 6.0 mm (0.24 in) 

    Fig 7: Measuring Clutch Disc Thickness

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. 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): 1.35 - 1.95 mm (0.053 - 0.077 in) 

    Service Limit: 0.7 mm (0.03 in) 

    Fig 8: Measuring Depths Of Rivets From Clutch Disc Lining Surface And Rivets

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Flywheel Inspection 

12. Remove the ring gear holder.
13. Inspect the ring gear teeth for wear and damage.
14. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
15. Measure the flywheel (A) runout using a dial indicator (B). Through at least two full turns with pushing against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the measurement is not within the standard, replace the flywheel, and recheck the runout; go to step 16.

    Standard (New): 0.3 mm (0.01 in) max. 

    Service Limit: 0.4 mm (0.02 in) 

    Fig 9: Measuring Flywheel Runout Using Dial Indicator

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Flywheel Replacement 

16. Install the ring gear holder (A).
    Fig 10: Identifying Ring Gear Holder

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
17. Loosen the flywheel mounting bolts in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel and the ring gear holder.
18. Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.
19. Install the ring gear holder (A), then torque the flywheel mounting bolts (B) in a crisscross pattern in several steps.
    Fig 11: Ring Gear Holder And Flywheel Mounting Bolts With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Pilot Bearing Inspection 

20. Turn the inner race of the pilot bearing with your finger. The pilot bearing should turn smoothly and quietly. Check that the pilot bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the pilot bearing; go to step 21.
    Fig 12: Turning Inner Race Of Pilot Bearing

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
21. Remove the pilot bearing (A) using the slide hammer (B), the remover handle (C), and the 20 mm bearing remover shaft set (D).
    Fig 13: Removing Pilot Bearing Using Slide Hammer And Remover Handle

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
22. Install a new pilot bearing (A) into the crankshaft using the 15 x 135L driver handle (B) and the 22 x 24 mm attachment (C).
    Fig 14: Installing Pilot Bearing Into Crankshaft Using Driver Handle

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Clutch Disc and Pressure Plate Installation 

23. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
24. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B), then install the clutch disc using the clutch alignment tool set (C) and the 20 mm clutch alignment pilot (D).
    Fig 15: Identifying Grease Applying Area On Splines Of Clutch Disc

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
25. Align (±60 degrees) the point marks (A) across the pressure plate (B) and the flywheel (C).
    Fig 16: Identifying Point Marks, Pressure Plate, Flywheel And Mounting Bolts

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
26. Install the pressure plate and the mounting bolts (D), finger-tight.
27. Torque the mounting bolts (A) in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. Make sure that there is not clearance between the pressure plate and the flywheel.

    Specified Torque: 25 N.m (2.6 kgf.m, 19 lbf.ft) 

    Fig 17: Tighting Ring Gear Mounting Bolts

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
28. Remove the ring gear holder (B), the clutch alignment tool set (C), and the 20 mm clutch alignment pilot.
29. Make sure the diaphragm spring fingers are all the same height.
30. Do the release bearing inspection, and replace it if necessary.
31. Install the transmission (see TRANSMISSION INSTALLATION ).