Clutch Release Fork: Service and Repair

CLUTCH RELEASE SYSTEM
REMOVAL





1. Drive out No.1 bush (release arm side) by using special tool and hammer.

Special Tool
(A): 09922-46010





2. Remove release shaft and spring.
3. Remove No.2 bush by using a flat end rod or the like.

INSPECTION
1. Check clutch release bearing for its smooth rotation.
2. Inspect smoothness of input shaft bearing retainer and correct or replace it as necessary.

CAUTION: Do not wash release bearing. Washing may cause grease leakage and consequential bearing damage.

INSTALLATION





NOTE: DO NOT apply grease to No.1 and No.2 bush.

1. Install new No.2 bush.
2. Install release shaft with return spring.
3. Drive in a new No.1 bush until its end contacts stepped surface of clutch housing using special tools and hammer.

Special Tool
(B): 09925-98221
(C): 09927-34510





4. Set release arm to release shaft by aligning punch marks. Then tighten bolt.

Tightening Torque
(a): 23 Nm (2.3 kg-m, 17.0 ft. lbs.)

5. Hook return spring.
6. Apply grease to release shaft arm, then set bearing.





7. Apply small amount of grease (about 0.1 g) to input shaft spline and front end as well.

CAUTION: DO NOT apply grease to sliding portion of release bearing with bearing retainer. Release bearing itself has been lubricated there.

"A": Grease 99000-25010