Clutch Clearance Inspection

Special Tools Required

Clutch compressor attachment 07ZAE-PRP0100

Inspect the clutch piston, the clutch discs, the clutch plates, and the clutch 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 clutch piston in the clutch drum. Do not install the O-rings during inspection.

Fig 1: Identifying Clutch Drum And O-Rings
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the wave spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (5) and the clutch wave-plates (E) (4), then install the clutch end-plate (F) with the flat side toward the top disc.

Fig 2: Identifying Wave Spring, 1st Clutch Drum And Wave-Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the wave spring (A) in the 2nd clutch drum (B). Install the flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and the wave-plates (E) (5), then install the clutch end-plate (F) with the flat side toward the top disc.

Fig 3: Identifying Wave Spring, Clutch Drum And Clutch Disc
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the wave spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C), then starting with the clutch disc, alternately install the clutch discs (D) (6) and clutch wave-plates (E) (5), then install the clutch end-plate (F) with the flat side toward the top disc.

Fig 4: Identifying Wave Spring, 3rd Clutch Drum And Clutch Flat-Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and the clutch discs (D) (4), then install the clutch end-plate (E) with the flat side toward the top disc.

Fig 5: Identifying Wave Spring, 4th Clutch Drum And Clutch Disc
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and the clutch discs (D) (4), then install the clutch end-plate (E) with the flat side toward the top disc.

Fig 6: Identifying Wave Spring, 5th Clutch Drum And Clutch Wave-Plates
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the snap ring using a screwdriver.

Fig 7: Installing Snap Ring
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Set a dial indicator (A) on the clutch end-plate (B).

Fig 8: Setting Dial Indicator On 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 clutch end-plate (A).

Fig 9: Releasing Clutch End-Plate To Lower Clutch 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 top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
Clutch End-Plate and Top Disc Clearance

Service Limit:

1st Clutch: 1.38-1.58 mm (0.054-0.062 in.)

2nd Clutch: 1.14-1.34 mm (0.045-0.053 in.)

3rd Clutch: 1.23-1.43 mm (0.048-0.056 in.)

4th Clutch: 0.93-1.13 mm (0.037-0.044 in.)

5th Clutch: 0.93-1.13 mm (0.037-0.044 in.)

If the clearance is out of the service limit, select a new clutch end-plate from the following tables; use the respective table with the same as the letters (RZH 00, RZK 00, or RCL A0) stamped on the top of the clutch end-plate. Always use the replacement end-plate with the same letters as the old one.

Fig 10: Identifying Clutch End-Plates Thickness

Courtesy of AMERICAN HONDA MOTOR CO., INC.

1ST CLUTCH RZH 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22571-RZH-003	2.6 mm (0.102 in.)
2	22572-RZH-003	2.7 mm (0.106 in.)
3	22573-RZH-003	2.8 mm (0.110 in.)
4	22574-RZH-003	2.9 mm (0.114 in.)
5	22575-RZH-003	3.0 mm (0.118 in.)
6	22576-RZH-003	3.1 mm (0.122 in.)
7	22577-RZH-003	3.2 mm (0.126 in.)
8	22578-RZH-003	3.3 mm (0.130 in.)
9	22579-RZH-003	3.4 mm (0.134 in.)

RZK 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22571-RZK-003	2.6 mm (0.102 in.)
2	22572-RZK-003	2.7 mm (0.106 in.)
3	22573-RZK-003	2.8 mm (0.110 in.)
4	22574-RZK-003	2.9 mm (0.114 in.)
5	22575-RZK-003	3.0 mm (0.118 in.)
6	22576-RZK-003	3.1 mm (0.122 in.)
7	22577-RZK-003	3.2 mm (0.126 in.)
8	22578-RZK-003	3.3 mm (0.130 in.)
9	22579-RZK-003	3.4 mm (0.134 in.)

RCL A0 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22571-RCL-A01	2.6 mm (0.102 in.)
2	22572-RCL-A01	2.7 mm (0.106 in.)
3	22573-RCL-A01	2.8 mm (0.110 in.)
4	22574-RCL-A01	2.9 mm (0.114 in.)
5	22575-RCL-A01	3.0 mm (0.118 in.)
6	22576-RCL-A01	3.1 mm (0.122 in.)
7	22577-RCL-A01	3.2 mm (0.126 in.)
8	22578-RCL-A01	3.3 mm (0.130 in.)
9	22579-RCL-A01	3.4 mm (0.134 in.)

2ND CLUTCH RZH 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
10	22569-RZH-003	2.4 mm (0.094 in.)
11	22570-RZH-003	2.5 mm (0.098 in.)
1	22571-RZH-003	2.6 mm (0.102 in.)
2	22572-RZH-003	2.7 mm (0.106 in.)
3	22573-RZH-003	2.8 mm (0.110 in.)
4	22574-RZH-003	2.9 mm (0.114 in.)
5	22575-RZH-003	3.0 mm (0.118 in.)
6	22576-RZH-003	3.1 mm (0.122 in.)
7	22577-RZH-003	3.2 mm (0.126 in.)

RZK 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
10	22569-RZK-003	2.4 mm (0.094 in.)
11	22570-RZK-003	2.5 mm (0.098 in.)
1	22571-RZK-003	2.6 mm (0.102 in.)
2	22572-RZK-003	2.7 mm (0.106 in.)
3	22573-RZK-003	2.8 mm (0.110 in.)
4	22574-RZK-003	2.9 mm (0.114 in.)
5	22575-RZK-003	3.0 mm (0.118 in.)
6	22576-RZK-003	3.1 mm (0.122 in.)
7	22577-RZK-003	3.2 mm (0.126 in.)

RCL A0 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
10	22569-RCL-A01	2.4 mm (0.094 in.)
11	22570-RCL-A01	2.5 mm (0.098 in.)
1	22571-RCL-A01	2.6 mm (0.102 in.)
2	22572-RCL-A01	2.7 mm (0.106 in.)
3	22573-RCL-A01	2.8 mm (0.110 in.)
4	22574-RCL-A01	2.9 mm (0.114 in.)
5	22575-RCL-A01	3.0 mm (0.118 in.)
6	22576-RCL-A01	3.1 mm (0.122 in.)
7	22577-RCL-A01	3.2 mm (0.126 in.)

3RD CLUTCH RZH 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22551-RZH-003	2.1 mm (0.083 in.)
2	22552-RZH-003	2.2 mm (0.087 in.)
3	22553-RZH-003	2.3 mm (0.091 in.)
4	22554-RZH-003	2.4 mm (0.094 in.)
5	22555-RZH-003	2.5 mm (0.098 in.)
6	22556-RZH-003	2.6 mm (0.102 in.)
7	22557-RZH-003	2.7 mm 0.106 in.)
8	22558-RZH-003	2.8 mm (0.110 in.)
9	22559-RZH-003	2.9 mm (0.114 in.)

RZK 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22551 -RZK-003	2.1 mm (0.083 in.)
2	22552-RZK-003	2.2 mm (0.087 in.)
3	22553-RZK-003	2.3 mm (0.091 in.)
4	22554-RZK-003	2.4 mm (0.094 in.)
5	22555-RZK-003	2.5 mm (0.098 in.)
6	22556-RZK-003	2.6 mm (0.102 in.)
7	22557-RZK-003	2.7 mm (0.106 in.)
8	22558-RZK-003	2.8 mm (0.110 in.)
9	22559-RZK-003	2.9 mm (0.114 in.)

RCL A0 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22551-RCL-A01	2.1 mm (0.083 in.)
2	22552-RCL-A01	2.2 mm (0.087 in.)
3	22553-RCL-A01	2.3 mm (0.091 in.)
4	22554-RCL-A01	2.4 mm (0.094 in.)
5	22555-RCL-A01	2.5 mm (0.098 in.)
6	22556-RCL-A01	2.6 mm (0.102 in.)
7	22557-RCL-A01	2.7 mm (0.106 in.)
8	22558-RCL-A01	2.8 mm (0.110 in.)
9	22559-RCL-A01	2.9 mm (0.114 in.)

4TH and 5TH CLUTCHES RZH 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22581-R91-003	2.1 mm (0.083 in.)
2	22582-R91-003	2.2 mm (0.087 in.)
3	22583-R91-003	2.3 mm (0.091 in.)
4	22584-R91-003	2.4 mm (0.094 in.)
5	22585-R91-003	2.5 mm (0.098 in.)
6	22586-R91-003	2.6 mm (0.102 in.)
7	22587-R91-003	2.7 mm (0.106 in.)
8	22588-R91-003	2.8 mm (0.110 in.)
9	22589-R91-003	2.9 mm (0.114 in.)

RZK 00 END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22581-R93-003	2.1 mm (0.083 in.)
2	22582-R93-003	2.2 mm (0.087 in.)
3	22583-R93-003	2.3 mm (0.091 in.)
4	22584-R93-003	2.4 mm (0.094 in.)
5	22585-R93-003	2.5 mm (0.098 in.)
6	22586-R93-003	2.6 mm (0.102 in.)
7	22587-R93-003	2.7 mm (0.106 in.)
8	22588-R93-003	2.8 mm (0.110 in.)
9	22589-R93-003	2.9 mm (0.114 in.)

RCL AO END-PLATES

THICKNESS CHART

Mark	Part Number	Thickness
1	22581-R90-003 or 22581-R91-003	2.1 mm (0.083 in.)
2	22582-R90-003 or 22582-R91-003	2.2 mm (0.087 in.)
3	22583-R90-003 or 22583-R91-003	2.3 mm (0.091 in.)
4	22584-R90-003 or 22584-R91-003	2.4 mm (0.094 in.)
5	22585-R90-003 or 22585-R91-003	2.5 mm (0.098 in.)
6	22586-R90-003 or 22586-R91-003	2.6 mm (0.102 in.)
7	22587-R90-003 or 22587-R91-003	2.7 mm (0.106 in.)
8	22588-R90-003 or 22588-R91-003	2.8 mm (0.110 in.)
9	22589-R90-003 or 22589-R91-003	2.9 mm (0.114 in.)

Install the new clutch end-plate, and 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 plates.

NOTE: When replacing the clutch wave-plates of the 4th or 5th clutch stamped on the end-plate with RCL A0, select the part number (22653-R90-003 or 22653-R91-003) of the wave-plates with the same mid-part number (XXXXX-R90-XXX or XXXXX-R91-XXX) of the clutch end-plate.