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 (0.024 in) max. 

   Service Limit: 0.8 mm (0.031 in) 

   Fig 1: Checking Evenness Of Height Of Diaphragm Spring Fingers Using Clutch Alignment Disc (A), Clutch Alignment Shaft (B), Remover Handle (C), And A Feeler Gauge (D)

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Install the ring gear holder (A), the remover handle (B), and the clutch alignment shaft (C).
   Fig 2: Identifying Ring Gear Holder (A), Remover Handle (B) And Clutch Alignment Shaft (C)

   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 (A)

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6. Inspect the pressure plate surface (A) for wear, cracks, and burning.
   Fig 4: Identifying Pressure Plate Surface (A)

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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): 0.08 mm (0.0031 in) max. 

   Service Limit: 0.15 mm (0.0059 in) 

   Fig 5: Inspecting For Warpage Using A Straight Edge (A) And A Feeler Gauge (B), Measuring Across Pressure Plate (C)

   Courtesy of AMERICAN HONDA MOTOR CO., INC.

   Clutch Disc Inspection and Removal 

8. Remove the clutch disc (A), the remover handle (B), and the clutch alignment shaft (C).
   Fig 6: Identifying Clutch Disc (A), Remover Handle (B) And Clutch Alignment Shaft (C)

   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): 7.30-7.90 mm (0.2874-0.3110 in) 

    Service Limit: 6.0 mm (0.236 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): 1.15-1.75 mm (0.0453-0.0689 in) 

    Service Limit: 0.7 mm (0.028 in) 

    Fig 8: Measuring Depths Of Rivets From Clutch Disc Lining Surface (A) To Rivets (B) On Both Sides

    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): 0.05 mm (0.0020 in) max. 

    Service Limit: 0.15 mm (0.0059 in) 

    Fig 9: Identifying Flywheel (A) And Dial Indicator (B)

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Flywheel Replacement 

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

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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 (A) And Flywheel Mounting Bolts (B) With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Crankshaft Pilot Bushing Inspection 

20. Inspect the crankshaft pilot bushing for wear and damage.
21. Inspect the inside surface of the crankshaft pilot bushing with your finger. If the crankshaft pilot bushing is not smooth, replace it; go to step 22.
    Fig 12: Inspecting Inside Surface Of Crankshaft Pilot Bushing With Finger

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Crankshaft Pilot Bushing Replacement 

22. Remove the crankshaft pilot bushing (A) using the slide hammer (B), the remover handle (C), and the 20 mm bearing remover shaft set (D).
    Fig 13: Identifying Crankshaft Pilot Bushing (A), Slide Hammer (B), Handle (C) And Bearing Remover Shaft Set (D)

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

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    Clutch Disc and Pressure Plate Installation 

24. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
25. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing (A).
    Fig 15: Identifying Crankshaft Pilot Bushing (A), Super High Temp Urea Grease To Splines (B)

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26. Apply super high temp urea grease (P/N 08798-9002) to the splines (B) of the clutch disc (C), then install the clutch disc using the remover handle (D) and the clutch alignment shaft (E).
27. Install the pressure plate (A) and the mounting bolts (B) finger-tight.
    Fig 16: Identifying Pressure Plate Mounting Bolts (A) In A Crisscross Pattern

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
28. Torque the pressure plate mounting bolts (A) in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. Make sure that there is no clearance between the pressure plate and the flywheel.
    Fig 17: Identifying Pressure Plate Mounting Bolts (A), Ring Gear Holder (B) And Clutch Alignment Shaft (C)

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