Clutch Release Bearing: Service and Repair

Release Bearing and Lever

REMOVAL
NON-TURBO MODEL
1) Remove the transmission assembly from vehicle body.
2) Remove the two clips from clutch release lever and remove the release bearing.

CAUTION: Be careful not to deform the clips.





3) Remove the release lever seal.





4) Remove the release lever retainer spring from release lever pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever.

TURBO MODEL
1) Remove the transmission assembly from vehicle body.
2) Remove the clutch release lever from transmission.
3) Put the clutch release bearing in engine side.





4) Remove the clutch release bearing from clutch cover using a flat-type screwdriver.

INSTALLATION
NON-TURBO MODEL

CAUTION: Before or during assembling, lubricate the following points with a light coat of grease.
^ Contact surface of lever and pivot
^ Contact surface of lever and bearing
^ Transmission main shaft spline (Use grease containing molybdenum disulphide.)
^ Contact surface of lever and operating cylinder





1) While pushing the release lever to pivot and twisting it to both sides, fit the retainer spring onto the constricted portion of pivot.

NOTE:
^ Apply grease (SUNLIGHT 2: P/N 003602010) to the contact point of release lever and operating cylinder.
^ Confirm that the retainer spring is securely fitted by observing it through the main case hole.

2) Install the release bearing and fasten it with two clips.





3) Install the release lever seal.
4) Install the transmission assembly.

TURBO MODEL
1) Install the release bearing on transmission.





2) Insert the release fork into release bearing tab.





3) Apply grease to the specified points:
^ Spline FX2200
^ Shaft SUNLIGHT 2





4) Insert the release fork shaft into release fork.

CAUTION: Make sure the cutout portion of the release fork shaft contacts spring pin.

5) Install the transmission assembly.

INSPECTION
RELEASE BEARING

CAUTION: Since this bearing is grease sealed and is of a non-lubrication type, do not wash with gasoline or any solvent when servicing the clutch.





1) Check the bearing for smooth movement by applying force in the radial direction.
Radial direction stroke: 1.4 mm (0.055 inch)





2) Check the bearing for smooth rotation by applying pressure in the thrust direction.
3) Check wear and damage of bearing case surface contacting with lever.

RELEASE LEVER





1) Check the lever pivot portion and the point of contact with release bearing case for wear.