Engine Side

Pressure Plate Inspection and Removal 

1. Remove the transmission (see NEUTRAL POSITION SWITCH REPLACEMENT ).
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 Height Of Diaphragm Spring Fingers Using Clutch Alignment Disc, Clutch Alignment Shaft, Remover Handle And Feeler Gauge

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Install the ring gear holder (A), the 150 mm ring gear bolt set (B), the clutch alignment shaft (C), and the remover handle (D).
   Fig 2: Identifying Ring Gear Holder, Clutch Alignment Shaft, Ring Gear Bolts And Pressure Plate With Mounting Bolts

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. To prevent warping, unscrew the pressure plate mounting bolts (E) in a crisscross pattern in several steps, then remove the pressure plate (F).
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 (A) surface for wear, cracks, and burning.
   Fig 4: Identifying Pressure Plate

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Inspect for warpage using a precision straight edge (A) and 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): 0.03 mm (0.0012 in) max. 

   Service Limit: 0.15 mm (0.0059 in) 

   Fig 5: Inspecting Warpage Using Precision 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 shaft (B), and the remover handle (C).
   Fig 6: Identifying Clutch Disc, Clutch Alignment Shaft And Remover Handle

   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): 8.3-9.0 mm (0.327-0.354 in) 

    Service Limit: 6.5 mm (0.256 in) 

    Fig 7: Measuring Clutch Disc Thickness

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
11. Measure the depth of the rivet 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): 1.2-1.7 mm (0.047-0.067 in) 

    Service Limit: 0.4 mm (0.016 in) 

    Fig 8: Measuring Depth Of Rivet From Clutch Disc Lining Surface To 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): 0.05 mm (0.0020 in) max. 

    Service Limit: 0.15 mm (0.0059 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) and the 150 mm ring gear bolt set (B).
    Fig 10: Identifying Ring Gear Holder, Flywheel On Crankshaft, Ring Gear And Flywheel Mounting Bolts

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
17. Loosen the flywheel mounting bolts (C) in a crisscross pattern in several steps. Remove the bolts, then remove the flywheel (D) and the ring gear holder.
18. Apply a small amount of engine oil to the seating surface of the flywheel mounting bolts (A).
    Fig 11: Ring Gear Holder, Flywheel On Crankshaft, Ring Gear And Flywheel Mounting Bolts With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
19. Install the flywheel (B) on the crankshaft (C), and install the mounting bolts finger-tight.
20. Install the ring gear holder (D) and the 150 mm ring gear bolt set (E), then torque the flywheel mounting bolts in a crisscross pattern in several steps.

    Crankshaft Pilot Bushing Inspection 

21. Inspect the crankshaft pilot bushing for wear and damage.
22. 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  23.
    Fig 12: Inspecting Crankshaft Pilot Bushing For Wear And Damage

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Crankshaft Pilot Bushing Replacement 

23. Remove the crankshaft pilot bushing (A) using the 15 mm bearing remover shaft set (B) and the slide hammer (C).
    Fig 13: Removing Crankshaft Pilot Bushing Using Bearing Remover Shaft And Slide Hammer

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

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    Clutch Disc and Pressure Plate Installation 

25. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.
26. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the crankshaft pilot bushing (A).
    Fig 15: Identifying Applied Urea Grease On Crankshaft Pilot Bushing And Splines Of Clutch Disc

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
27. 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 clutch alignment shaft (D) and the remover handle (E).
28. Install the pressure plate (A) and the mounting bolts (B) finger-tight.
    Fig 16: Identifying Pressure Plate With Mounting Bolts

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
29. 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 (2.5 kgf.m, 18 lbf.ft) 

    Fig 17: Identifying Ring Gear Holder, Clutch Alignment Shaft, Remover Handle, Pressure And Ring Gear Bolts

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
30. Remove the ring gear holder (B), the 150 mm ring gear bolt set (C), the clutch alignment shaft (D), and the remover handle (E).
31. Make sure the diaphragm spring fingers are all the same height.
32. Do the release bearing inspection, and replace it if necessary.
33. Install the transmission (see TRANSMISSION INSTALLATION ).