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Model SG CLUTCH 5-9

6. REMOVE THE CLUTCH COVER AND COMPRESSION

SPRINGS.
1. Slowly release the press.
2. Remove the clutch cover, compression springs and
spring seats.
NOTE: Before disassembling, put the match marks
on the cover and pressure plate.

SM5-055 SM5-055
Fig. 13
7. REMOVE THE RELEASE LEVER ASSEMBLY.
1. Remove the cotter pin and plain washer.
2. Remove the pin and release lever.
NOTE: Hammering on the boss of the pressure plate
is prohibited (to prevent damage to the boss
parts).

SM5-057
Fig. 14
3. Remove the cotter pin, plain washer and torsion
spring.
4. Using a copper hammer, remove the pin.
5. Separate the release lever from release lever sup-
port.

SM5-057 SM5-057B
Fig. 15
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5-10 CLUTCH Model SG

INSPECTION AND REPLACEMENT

1. INSPECT THE CLUTCH DISC.
1. Check the damper springs for breakage or play.
If any breakage or play is detected, replace the clutch
disc assembly.

SM5-049B
Fig. 16
2. Check the clutch disc for cracks and loose stopper
pin.
If any of these conditions is present, replace the
clutch disc assembly.

SM5-050B
Fig. 17
3. Using a feeler gauge, measure the clearance be-
CLUTCH DISC tween clutch disc and transmission input shaft spline.
CLEARANCE If the clearance is greater than service limit, replace
the clutch disc or input shaft.
Assembly Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in.)
INPUT
SHAFT Service Limit: 0.5 mm (0.020 in.)

Fig. 18
4. Using a dial gauge, measure the clutch disc runout.
If the runout is greater than service limit, replace the
clutch disc assembly.
Assembly Standard: 0 - 1.2 mm (0 - 0.047 in.)
Service Limit: More than 1.2 mm (0.047 in.)

Fig. 19
RIVET HEAD DEPTH 5. Using a vernier caliper, measure the facing thickness
FACING THICKNESS and/or the rivet head depth. If the thickness or the
head depth is less than service limit, replace the
clutch disc assembly.

Facing thickness Rivet head depth

Standard 4.75 mm (0.1870 in.) 2.75 mm (0.1083 in.)
Service limit 3.6 mm (0.142 in.) 1.6 mm (0.063 in.)
SM5-064A
Fig. 20
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Model SG CLUTCH 5-11

2. INSPECT THE COMPRESSION SPRING.

1. Measure the free length of all springs.
If the spring free length is less than service limit, re-
place the spring.
Clutch booster less
Standard: 88.5 mm (3.484 in.)
Service Limit: 84.1 mm (3.311 in.)
With clutch booster
SM5-068 Standard: 92.9 mm (3.657 in.)
Fig. 21
Service Limit: 88.3 mm (3.476 in.)

2. Using a steel square, measure the squareness.

If the spring is out of square, replace the spring.
Service Limit: 5.0 mm (0.197 in.)

SM5-068
3. Using a spring tester, measure the tension of each
Fig. 22
spring at the specified setting length. If the tension
is less than service limit, replace the spring.
Clutch booster less
Standard: 116.4 kg (257 lb.)
Service Limit: 98.8 kg (218 lb.)
Setting Length: 59.6 mm (2.346 in.)
With clutch booster
Standard: 131 kg (289 lb.)
Service Limit: 112.8 kg (249 lb.)
SM5-068 Setting Length: 59.6 mm (2.346 in.)
Fig. 23
3. INSPECT THE PRESSURE PLATE.
1. Using a straight edge and a feeler gauge, check the
face runout of the pressure plate.
If the runout is greater than the repair limit, regrind
or replace the pressure plate.
Standard: 0 - 0.1 mm (0 - 0.003 in.)
Repair Limit: 0.5 mm (0.020 in.)

SM5-038
Fig. 24
2. Using a vernier caliper, measure the pressure plate
thickness.
If the thickness is less than service limit, replace the
pressure plate.
Standard: 23 mm (0.91 in.)
Service Limit: 22 mm (0.87 in.)

PRESSURE PLATE THICKNESS

Fig. 25
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5-12 CLUTCH Model SG

3. Check the friction surface for scoring or heat crack-

ing.
If necessary, regrind the friction surface or replace
the pressure plate.

SM5-038A
Fig. 26
4. INSPECT THE COMPONENT PARTS OF THE RELEASE
LEVER.
Check the release lever, bushing, and pin for wear
or damage.
If necessary, replace the parts.

SM5-077A
Fig. 27
5. INSPECT THE FLYWHEEL.
1. Check the friction surface for scoring or heat crack-
ing.
If necessary, grind the friction surface or replace the
flywheel.
Grind limit: 1 mm (0.039 in)
Deflection limit: 0.04 mm (0.00157 in.)
NOTE: Do not grind the flywheel over than the limit.
SM5-098
Fig. 28
2. Using a vernier caliper, check the friction surface
A
ware.
If the wear is greater than the sevice limit, replace
the flywheel.
Standard: 48 mm (1.890 in.)
Service limit: 49 mm (1.929 in.)

SM5-040
Fig. 29

BOSS 3. After grind the friction surface, adjust the friction sur-
face depth of the flywheel within the service stand-
ard by grind the outer bosses of the flywheel.
Fly wheel depth: 48 mm (1.890 in.)

FRICTION
SURFACE

SM5-098
Fig. 30