e7e4e0628adf5c7ef565cd0956132dc8d3ce6c51457523822b52e8aa19be7ae3

nsxb12005a.pdf

Clutch Master Cylinder
Removal
1. Disconnect the clutch pipe from the clutch master
cylinder.
2. Pry out the cotter pin, and pull the clevis pin out of
the clevis.
3. Remove the nuts. COTTER PIN
Replace.
CLEVIS PIN
4. Remove the reservoir from the front compartment,
then remove the clutch master cylinder.
5. Disconnect the reservoir hose from the clutch
master cylinder, then remove the reservoir.
CAUTION:
• Avoid spilling brake fluid on paint as it may
damage the finish.
• Plug the end of the clutch pipe and reservoir
hose with a shop towel to prevent fluid from
flowing out of the clutch pipe and reservoir hose
after disconnecting.
CLUTCH PIPE
CLUTCH
MASTER
CYLINDER
RESERVOIR HOSE
RESERVOIR
Installation
1. Install the clutch master cylinder in the reverse
order of removal.
NOTE: Bleed the clutch hydraulic system (see
page 12-6).
RESERVOIR CAP
RESERVOIR SEAL
6 x 1.0 mm
10 N-m (1.0 kg-m,
7 Ib-ft)
FLOAT
RESERVOIR
10 N-m (1.0 kg-m, 7 Ib-ft)
CLUTCH MASTER CYLINDER
Inspect the cylinder wall
for scoring and wear.
RESERVOIR
HOSE
22 N-m
(2.2 kg-m,
16 Ib-ft)
COTTER PIN
Replace.
HOSE JOINT
10 N-m (1.0 kg-m, 7 Ib-ft)
NUTS
CLEVIS PIN
WASHER
Replace.

Attachments

6cda3ffa439837a9ab899801fbf13ccb64c2a4631804fb93058279e64856edce

nsxb12017a.pdf

Replacement
1. Remove the flywheel mounting bolts in a criss-
cross pattern in several steps, and remove the
flywheel.
MOUNTING BOLTS
FLYWHEEL
RING GEAR HOLDER
07LAB – PV00100 or
07924 – PD20003
2. Remove the ball bearing from the flywheel.
DRIFT
PUNCH
FLYWHEEL
BALL BEARING
3. Drive the new ball bearing into the flywheel using
the special tools as shown.
DRIVER
07749 – 0010000
ATTACHMENT,
37 x 40 mm
07746 – 0010200
FLYWHEEL
BALL BEARING
4. Align the holes in the flywheel with the mounting
bolt holes, then install the flywheel. Install the bolts
finger tight.
5. Install the special tool, then torque the flywheel
mounting bolts in a crisscross pattern in several
steps as shown.
MOUNTING BOLT
12 x 1.0 mm
105 N-m (10.5 kg-m, 76 Ib-ft)
RING GEAR HOLDER
07LAB – PV00100 or
07924 – PD20003
FLYWHEEL

Attachments

9496ae14e84b056c42f05beb62a2922192e7403dfad92b4fbbeee7db84792d01

nsxb12011a.pdf

Pressure Plate
Inspection
NOTE: If replacement is required, always replace the
pressure plate, mid plate, and flywheel as a set.
1. Inspect the pressure plate surface for wear, cracks,
and burning.
2. Inspect the fingers of the diaphragm spring for
wear at the release bearing contact area.
3. Inspect for warpage using a straight edge and
feeler gauge.
NOTE: Measure across the pressure plate at three
points.
Standard (New): 0.03 mm (0.001 in) max.
Service Limit: 0.15 mm (0.006 in)
STRAIGHT EDGE
FEELER GAUGE
PRESSURE PLATE
If the warpage is more than the service limit, replace
the pressure plate.
Release Bearing
Inspection
1. Check the release bearing for excessive play by
spinning it by hand.
CAUTION: Do not wash the release bearing in
solvent.
2. Replace the release bearing with a new one if there
is excessive play.
RELEASE
BEARING

Attachments

41759158a355d8256f5707dba219d259faa16afebe77c9521761bb4f0f51e673

nsxb12013a.pdf

Mid Plate
Inspection
NOTE: If replacement is required, always replace the
pressure plate, mid plate, and flywheel as a set.
1. Inspect the mid plate surface for wear, cracks, and
burning.
2. Inspect for warpage using a straight edge and
feeler gauge.
NOTE: Measure across the mid plate at three points.
Standard: (New): 0.05 mm (0.002 in) max.
Service Limit: 0.15 mm (0.006 in)
STRAIGHT EDGE
MID PLATE
FEELERGAUGE
If the warpage is more than the service limit, replace
the mid plate.
After Pressing:
MID PLATE GUIDE
Before Pressing:
MID PLATE
The mid plate guides are the self-adjusting mechanisms
for the mid plate.
NOTE: Make sure all parts are clean before inspection.
Check the mid plate guides by pushing down on each of
the guides by hand (10–60 kg). The mid plate guides
should compress and lock in place.
If the mid plate guides do not move or compress, disas-
semble the mid plate guides and inspect them for debris,
wear and damage. Refer to page 12-15 (’93-’96), 12-17
(’91-’92 Models).
Inspection
Mid Plate Guide

Attachments

d2f62580817dc2590e5b3e2f934fa145de84d13092bae7a4d05cde29f393182e

nsxb12006a.pdf

Slave Cylinder
Removal
1. Disconnect the clutch hose from the slave cylinder.
CAUTION:
• Avoid spilling brake fluid on the painted sur-
faces, as it may damage the finish.
• Plug the end of the clutch hose with a shop
towel to prevent brake fluid from coming out.
2. Remove the slave cylinder from the clutch housing.
SLAVE
CYLINDER
CLUTCH
HOSE
O-RING
Replace.
BOOT
Remove and check for signs of leaking
and deterioration.
Installation
Super High Temp Urea Grease (P/N
08798-9002).
Brake Assembly Lube or equivalent rubber
grease.
1. Install the slave cylinder on the clutch housing.
SLAVE CYLINDER
8 x 1.25 mm
22 N-m (2.2 kg-m,
16 Ib-ft)
10 N-m (1.0 kg-m,
7 Ib-ft)
(P/N 08798-9002)
(Brake Assembly
Lube)
2. Bleed the clutch hydraulic system:
• Attach a hose to the bleeder screw, then suspend
the hose in a container of brake fluid.
• Make sure there is an adequate supply of fluid at
the master cylinder, then slowly pump the
clutch pedal until no more bubbles appear at the
bleeder hose.
• Refill the master cylinder fluid when done.
• Use only DOT 3 or 4 brake fluid.
6 x 1.0 mm
10 N-m (1.0 kg-m,
7 Ib-ft)

Attachments

2c92109680538fb48d7d813596c576c13feed91fdf1c92bb1ff16a6ae5ac4280

nsxb12002a.pdf

Special Tools
Ref.No. Tool Number
07LAB — PV00100 or
07924 — PD20003
07MAF—PR80100
07746 — 0010200
07749 — 0010000
07936 — 3710100
Description
Ring Gear Holder
Clutch Alignment Shaft
Attachment, 37 x 40 mm
Driver
Handle
Qty Page Reference
12-10, 17,
18, 19
12-18, 19
12-17
12-17
12-18, 19
1
1
1
1
1

Attachments

a0cf3f4651d3cb39ca64e5c32049db66b2a1cc4cec5f791abf749383a0e83091

nsxb12008a.pdf

Clutch Master Cylinder (Canada)
Disassembly
CAUTION: Avoid spilling brake fluid on paint as it may
damage the finish.
1. Remove the dust seal from the clutch master
cylinder.
DUST SEAL
CIRCLIP
2. Pry the circlip off the clutch master cylinder.
3. Carefully remove the piston by applying air
pressure through the clutch line hole.
CAUTION:
• Hold a shop towel over the master cylinder to stop
the piston in case it comes out suddenly.
• Plug the end of the clutch hose port with a shop
towel to prevent fluid from coming out.
• Clean all disassembled parts in solvent, and blow
through all ports and passages with compressed
air.
PISTON
ASSEMBLY
SHOP TOWEL
MASTER
CYLINDER
BODY
Plug port.
Reassembly
CAUTION:
• Before assembling, make sure all parts are complete-
ly clean.
• Replace parts with new ones whenever specified to
do so.
• Do not allow dust or water to enter the system.
• Do not mix different brands of brake fluid as they
may not be compatible.
• Do not reuse the brake fluid which was drained out.
• Avoid spilling the brake fluid on painted surfaces as
it may damage the finish.
1. Assemble the piston noting the proper direction of
the parts (see page 12-7).
MASTER CYLINDER
BODY
(Brake Assembly
Lube)
Push the piston in until it engages
the pawl of the retainer.
2. Slide the piston assembly into the clutch master
cylinder.
3. Install the circlip in the groove in the clutch master
cylinder.
DUST SEAL
CIRCLIP
4. Install the dust seal.

Attachments

36f1f97c03d4a7760a92c4148fd44e7f3fd314757d3307a224de1a8b7c5cd794

nsxb12003a.pdf

Illustrated Index
NOTE:
Whenever the transmission is removed, clean and grease the release bearing sliding surface.
If the parts marked * are removed, the clutch hydraulic system must be bled.
Bleed the clutch hydraulic system (see page 12-6).
Inspect the hoses for damage, leaks, interference, and twisting.
FLYWHEEL
Inspection, page 12-16
Replacement, page 12-17
MID PLATE
Removal, page 12 -10
Inspection, page 12 -13
Installation, page 12 -18
2ND CLUTCH DISC
Removal, page 12-10
Inspection, page 12-12
Installation, page 12-18
DAMPER
WASHER
PRESSDRE PLATE
Removal, page 12-10
Inspection, page 12-11
Installation, page 12-18
TRANSMISSION
1ST CLUTCH DISC
Removal. page 12-10
Inspection, page 12-12
Installation, page 12-18
SPRING
COLLAR
RELEASE BEARING
Removal, page 12-10
Inspection, page 12-11
Installation, page 12-18
RELEASE FORK
SLAVE CYLINDER
•CLUTCH DAMPER
COTTER PIN
Replace.
0-RING
Replace.
*RESERVOIR HOSE
ASSIST SPRING
CLUTCH MASTER CYLINDER
MID PLATE GUIDE
Inspection. page 12 -13
Initialization. page 12-14
Replacement, page 12-15
*15 N·m (1.5 kg-m.
11 lb-ft)
*RESERVOIR
*19 N·m (1.9 kg-m.
14 lb-ft)
*CLUTCH PIPE
*19 N·m (1.9 kg-m,
14 Ib-ft)
*CLUTCH
HOSE
CLEVIS PIN
DOWEL PIN

Attachments

3dba5232a2e31194b5b2b1b7d69d343aed9315b6ac459e284e9fec0370deeb29

nsxb12018a.pdf

Pressure Plate, Clutch Disc, Mid Plate
Installation
NOTE:
• Install the pressure plate, clutch discs, and mid plate
as a set.
• Do not mix-up the 1st and 2nd clutch discs. The 2nd
clutch disc has a flat plate between the two friction
surfaces. The 1st clutch disc has a spring plate be-
tween the two friction surfaces.
• Use only Super High Temp Urea Grease (P/N
08798-9002).
1. Install the damper washer and spring collar.
SPRING COLLAR DAMPER WASHER
Turn the groove to
the out side.
2. Install the special tool.
3. Install the 2nd clutch disc using the special tools.
NOTE: The index mark on the 2nd clutch disc
should face away from the flywheel.
FLYWHEEL
2ND CLUTCH DISC
HANDLE
07936 – 3710100
(P/N 08798-9002)
CLUTCH ALIGNMENT SHAFT
07MAF – PR80100
RING GEAR HOLDER
07LAB – PV00100 or
07924 – PD20003
4. Install the mid plate.
NOTE: Align the mark on the flywheel with the
mark on the mid plate.
Align the marks.
FLYWHEEL
MID PLATE
5. Install the 1st clutch disc.
NOTE:
• The marks on the 1st and 2nd clutch discs
should be 180° apart.
• The index mark on the 1st clutch disc should
face away from the flywheel.
MARKS
1ST CLUTCH DISC
(P/N 08798-9002)

6. Install the release bearing on the pressure plate.
7. Install the pressure plate.
NOTE:
Align the mark on the mid plate with the mark on
the pressure plate.
After installing, make sure the release bearing is
secure.
Align the marks.
PRESSURE PLATE
RELEASE BEARING
PRESSURE PLATE
(P/N 08798-9002)
RELEASE
BEARING
Place the diaphragm spring fingers
in the groove of the release bearing.
9. Remove the special tools.
10. Initialize the mid plate guides (see page 12-14
(’93-’96), 12-16 (’91-’92 Models).
MOUNTING BOLT
8 x 1.25 mm
22 N·m (2.2 kg-m, 16 Ib-ft)
8. Torque the mounting bolts in a crisscross pattern
as shown. Tighten them several steps to prevent
warping the diaphragm spring.
NOTE: Place the diaphragm spring fingers in the
groove of the release bearing.

Attachments

52761d91c963f60bc63b8957a7171ff1bef5c43ebbd0922a593879328e39bdad

nsxb12014a.pdf

Mid Plate Guide
Initialization
NOTE:
• If the pressure plate mounting bolts are unscrewed,
the mid plate guide must be initialized.
• Initialize after tightening the pressure plate mount
bolts.
1. Screw the 5 mm bolt into the back of the flywheel
until it just touches the mid plate guide.
5 x 0.8 mm BOLT
Length of threads
10 mm (0.39 in)
1.5 N-m (0.15 kg-m,
1.1 Ib-ft)
MID PLATE
MID PLATE GUIDE 5 x 0.8 mmBOLT
2. Screw the 5 mm bolt in 1 50 — 210° further.
3. Make sure that:
• The mid plate guide touches the back of the mid
plate
• There is 0.25-0.40 mm (0.010-0.016 in)
clearance between the mid plate guide and the
front of the mid plate
4. Initialize the remaining mid plate guides as describ-
ed above, then remove the 5 mm bolt.

Attachments