Clutch Clearance Inspection

Special Tools Required 

Clutch Compressor Attachment 07ZAE-PRP0100

1. 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.
2. Install the clutch piston in the clutch drum. Do not install the O-rings on the clutch piston during inspection.
   Fig 1: Installing Clutch Piston In Clutch Drum

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
3. Install the wave spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
   Fig 2: Installing Clutch End-Plate With Flat Side Down On Top Disc

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
4. Install the wave spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
   Fig 3: Installing Wave Spring In 2Nd Clutch Drum

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
5. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
   Fig 4: Installing Clutch End-Plate (E) With Flat Side Down On Top Disc

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
6. Install the wave spring (A) in the 3rd clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
   Fig 5: Installing Wave Spring (A) In 3rd Clutch Drum

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
7. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
   Fig 6: Installing Wave Spring In 5Th Clutch Drum

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
8. Install the snap ring with a screwdriver to secure the clutch end-plate.
   Fig 7: Installing Snap Ring With Screwdriver

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
9. Set a dial indicator (A) on the clutch end-plate (B). A
   Fig 8: Setting A Dial Indicator On Clutch End-Plate

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
10. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
11. Release the clutch end-plate to lower it, then put the clutch compressor attachment on the end-plate (A).
    Fig 9: Putting Clutch Compressor Attachment On End-Plate

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
12. For the 1st, 3rd, and 5th clutches:

    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.

13. For 2nd and 4th clutches:

    Press the clutch compressor attachment down with 39 N (4 kgf, 9 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.

    Clearance between Clutch End-Plate and Top Disc 

    Service Limit 

    1st clutch: 1.62-1.82 mm (0.064-0.072 in) 

    2nd clutch: 0.5-0.7 mm (0.020-0.028 in) 

    3rd clutch: 0.73-0.93 mm (0.029-0.037 in) 

    4th clutch: 0.7-0.9 mm (0.028-0.035 in) 

    5th clutch: 0.73-0.93 mm (0.029-0.037 in) 

14. If the clearance of the 1st, 3rd, or 5th clutch is out of the service limit, select a new clutch end-plate from the following table.
    Fig 10: Measuring Clearance Between Clutch End-Plate And Top Disc

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    1ST, 3RD and 5TH CLUTCH END-PLATES 

    THICKNESS SPECIFICATIONS
    
    

    Mark	Thickness
    1	2.1 mm (0.083 in)
    2	2.2 mm (0.087 in)
    3	2.3 mm (0.091 in)
    4	2.4 mm (0.094 in)
    5	2.5 mm (0.098 in)
    6	2.6 mm (0.102 in)
    7	2.7 mm (0.106 in)
    8	2.8 mm (0.110 in)
    9	2.9 mm (0.114 in)

15. If the clearance of the 2nd or 4th clutch is out of the service limit, remove the clutch end-plate and check the clutch end-plate mark. Select a new clutch end-plate from the following tables by the mark on the old clutch end-plate. Use the AC-AL Plates table when the old clutch end-plate is marked with between AC and AL. Use the AM-AV Plates table when the old clutch end-plate is marked with between AM and AV.
    Fig 11: Measuring Clutch Clearance

    Courtesy of AMERICAN HONDA MOTOR CO., INC.

    2ND and 4TH CLUTCH END-PLATES AC-AL Plates 

    THICKNESS SPECIFICATIONS
    
    

    Mark	Thickness
    AC	2.1 mm (0.083 in)
    AD	2.2 mm (0.087 in)
    AE	2.3 mm (0.091 in)
    AF	2.4 mm (0.094 in)
    AG	2.5 mm (0.098 in)
    AH	2.6 mm (0.102 in)
    AJ	2.7 mm (0.106 in)
    AK	2.8 mm (0.110 in)
    AL	2.9 mm (0.114 in)

    AM-AV Plates 

    THICKNESS SPECIFICATIONS
    
    

    Mark	Thickness
    AM	L 2.1 mm (0.083 in)
    AN	2.2 mm (0.087 in)
    AP	2.3 mm (0.091 in)
    AQ	2.4 mm (0.094 in)
    AR	2.5 mm (0.098 in)
    AS	2.6 mm (0.102 in)
    AT	2.7 mm (0.106 in)
    AU	2.8 mm (0.110 in)
    AV	2.9 mm (0.114 in)

16. 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.