Check the height of the diaphragm spring fingers using the special tools and a feeler gauge. If the height is more than the service limit, replace the pressure plate and clutch disc as a set.

Standard (New):

0.8 mm (0.02 in.) max.

Remove the base plate (A) from the special tool.

Install the special tools to the engine is shown.

Turn the center screw (A) clockwise by hand to apply pressure on the diaphragm spring. Continue turning the center screw until it stops.

Loosen the pressure plate mounting bolts (A) in the pattern shown in several steps, then remove the bolts.

Turn the center screw on the pressure plate compressor counterclockwise by hand to release the pressure, then install two pressure plate mounting bolts, hand-tight, to hold the pressure plate (B). Remove the special tools and the pressure plate.

Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.

Inspect the surface of the pressure plate (A) for wear, cracks, and burning.

Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate and clutch disc as a set.

Standard (New):	0.03 mm (0.001 in.) max.
Service Limit:	0.15 mm (0.006 in.)

Remove the clutch disc and special tools.

Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is soaked with oil, replace it. Find the source of the oil leak if the clutch disc is soaked.

Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc and pressure plate as a set.

Standard (New):	7.6−8.0 mm (0.299−0.315 in.)
Service Limit:	6.0 mm (0.236 in.)

Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B) on both sides. If the rivet depth is less than the service limit, replace the clutch disc and the pressure plate as a set.

Standard (New):	1.1 mm (0.043 in.)
Service Limit:	0.3 mm (0.01 in.)

Inspect the crankshaft pilot bushing for wear and damage.

Inspect the inside surface of the crankshaft pilot bushing with your finger. If the crankshaft pilot bushing is not smooth, replace it.

Remove the crankshaft pilot bushing (A) using the special tools.

Install the new crankshaft pilot bushing (A) into the crankshaft using the special tools. Apply a light coat of urea grease UM264 (P/N 41211-PY5-305) to the crankshaft pilot bushing surface.

Inspect the ring gear teeth for wear and damage.

Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.

Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel and recheck the runout. Resurfacing the flywheel is not recommended.

Standard (New):

0.45 mm (0.018 in.) max.

Install the special tool.

Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.

Install the flywheel on the crankshaft, and install the mounting bolts finger-tight.

Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps.

NOTE: When installing the flywheel mounting bolts, apply engine oil to the seat surface of the flywheel mounting bolts.

Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.

Install the ring gear holder.

Apply urea grease UM264 (P/N 41211-PY5-305) to the splines (A) of the clutch disc (B), then install the clutch disc using the special tools.

Align a point marks (A) across the pressure plate (B) and flywheel (C).

Install the pressure plate and the mounting bolts (D), finger-tight.

Install the special tools.

Turn the center screw (A) clockwise by hand to apply pressure on the diaphragm spring.Continue turning the center screw unit it stops.

Be careful not to damage the pressure plate (A). Tighten (180 degrees apart) the pressure plate mounting bolts (B) in a star pattern in several steps.

Pressure Plate Mounting Bolt Torque:

25 N·m (2.6 kgf·m, 19 lbf·ft)

Turn the center screw on the pressure plate compressor counterclockwise by hand to release the pressure, then remove the special tools.

Make sure the diaphragm spring fingers are all the same height.

Remove the release fork boot (A) from the clutch housing (B).

Remove the release fork (C) from the clutch housing by squeezing the release fork set spring (D) with pliers. Remove the release bearing (E).

Check the release bearing for play by spinning it by hand. If there is excessive play, replace the release bearing with a new one.

NOTE: The release bearing is packed with grease. Do not wash it in solvent.

Apply urea grease UM264 (P/N 41211-PY5-305) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.

With the release fork slid between the release bearing pawls, install the release bearing on the mainshaft while inserting the release fork through the hole in the clutch housing.

Align the detent of the release fork with the release fork bolt, then press the release fork over the release fork bolt squarely.

Install the release fork boot (E). Make sure the boot seals around the release fork and clutch housing.

Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly.

NOTE: Learn to after installed the transmission.

Do the i-SHIFT system learning (dynamic mode).