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Section 1  Clutch Replacement

Hoist the engine from the compartment. See "Provison 20, Section 2, Chapter 2".

1. Remove manual transaxle assembly

2. Remove the clutch release fork. See (Figure 132)

3. Detach clutch release fork boot.

4. Detach clutch release bearing

5. Detach clutch release bearing fixed clamp

6. Remove clutch fork pivot pin

7. Align the clutch cover to the mark on the flywheel. Detach clutch cover. See (Figure 133)

8. Remove clutch plate

9. Check and remove clutch plate assembly. See (Figure 134)

10. Check clutch cover. See (Figure 135)

Depth wear: A: 0.6mm

Width wear: B: 5mm

Figure 132

Figure 133

Figure 134

Figure 135

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11. Using the dial gauge, check the flywheel runout. See

(Figure 136).

The maximum runout: 0.3mm

12. Check clutch release bearing

The bearing is permanently lubricated. There is no need to

lubricate or clean.

13. Check clutch plate

14. Install clutch cover. See (Figure 137)

Align the Clutch cover to the mark on the flywheel.

Hint:

(1) Uniformly tighten the bolt in the sequence shown.

Torque: 19 N. m

(2) Shake the clutch plate up and down, left and right to ensure

 it is centered, then tighten the bolt.

15. Check and adjust the clutch cover. See (Figure 138)

Check the diaphragm tip flatness with the dial gauge with roller.

Max. roughness: 0.5mm.

16. Install the release fork pivot pin

17. Install clutch release fork boot

18. Install clutch release bearing fixed clamp

19. Install clutch release fork

20. Install clutch release bearing

21. Install manual transaxle assembly

Figure 136

Figure 137

Figure 138

59

Chapter 8 Maunal Transaxle Assembly

 (MR7131A, MR7151A, MR7161A)

Component 1

Figure 139

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Section 1 Manual Transaxle Replacement

1. Open the engine hood

2. Remove the battery

3. Remove clutch cylinder sub-assembly. See (Figure 140)

4. Detach transmission shift cable assembly. See (Figure 141)

5. Remove the connector and turn on the back-up lamp switch connector.

6. Disconnect vehicle speed sensor

Disconnect vehicle speed sensor connector.

7. Detach the front exhaust pipe

8. Drain transmission oil

9. Detach left & right front wheel hub nut

10. Detach left & right front wheel speed sensor  (ABS)

11. Detach front balance rod

12. Detach left & right tie-rod with ball stud pin

13. Detach front balance rod

14. Detach left & right lower swing arm

15. Detach left & right front propeller assembly

16. Hoist the engine from compartment. See "Provision 20, Section 2, Chapter 2"

17. Detach starter assembly

18. Detach engine mounting bracket

19. Detach manual transaxle assembly

20. Install engine mounting bracket

21. Install manual transaxle assembly

22. Connect engine vibration insulating cushions

23. Install starter assembly

24. Install left & right front propeller assembly

25. Connect left & right lower swing arm

26. Connect left & right tie-rod with ball stud pin

27. Connect front balance rod

28. Connect left & right front speed sensor  (ABS)

29. Installleft & right front shaft nut

30. Install front exhaust pipe

31. Connect speedometer sensor connector.

32. Connect back-up lamp switch connector.

33. Connect transmission shift cable assembly. See (Figure 141)

34. Install clutch sub-pump assembly. See (Figure 140)

Figure 140

Figure 141