Manual Clutch System Repair

Repair of the Clutch System is one of the important components in a vehicle, whether manual, automatic, or motorcycle. Clutch lining or what is known as the clutch plate is a car engine that works as a successor of power that is transmitted from the engine to the transmission system.

The shape of this clutch is round like a disc and made of asbestos. But as with other car components, clutch linings can have problems or run out.

Manual Clutch System

All clutch pads on any brand or type of car of course have an age limit of use. This age of use is based on the time or distance traveled from the vehicle. In addition, whether or not the use of car clutch pads is also influenced by the driving style of the vehicle.

Under normal circumstances, the clutch lining of the car can wear out approximately after traveling a distance of 20,000 km
Before starting to check the car clutch lining, you should make sure the condition of your car is turned off. For safety, you can remove the battery to avoid certain risks.

Lift the car using a jack so that you can work more freely. You can also attach a jack stand for added safety. After disassembling the component parts then you can start checking it.

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The first components to be disassembled

Before you can disassemble the clutch units, you must first remove other components related to manual clutch system repair. Remove other components starting from the Propeller unit.

Start by removing the propeller shaft assembly, remove universal joint (four-way) fixing bolts on differential (gard). Then remove the propeller bearing retaining holder.

The first components to be disassembled

Next, remove the transmission unit and then disassemble the release bearing unit and the release fork will be carried along to the transmission housing (gerbox) so that it can be removed by removing the release fork lock on the shaft from the transmission housing. The release fork and release bearing will come off.


Removing the clutch unit is done by making marks on the clutch housing and fly wheel, then installing the center clutch or other tool to hold the clutch plate.

Loosen the clutch housing bolts to the fly wheel in a criss-cross sequence gradually and evenly, until the pressure is not there is spring pressure.

Remove the fixing bolts one by one and then remove the clutch cover and clutch disc.

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Release bearing check

Release bearings are generally closed bearing units with permanent lubrication type, so they do not require cleaning in their lubrication.

The first inspection that can be done is visually, by seeing if there is dirt, scrapes / burns, scratches or cracks. If there is dirt, scratch marks and it can only be slightly cleaned with fine sandpaper, if the damage is severe, replace it with a new unit.

Check the release bearing by turning the bearing by hand and applying force in the axial direction. If rough rotation or feel there is pressure should replace.

Hold the hub and case by hand then move it in all directions to ensure that the self-cantering system does not get stuck.

The hub and case should move approximately 1 mm. If the excitement is excessive or stuck, it should be replaced with a new one.

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Clutch cover check

Check clutch cover (diaphragm spring) for wear, measure wear the diaphragm spring uses a caliper as shown below, the depth limit = 0.6 mm and width = 5.0 mm, if the wear exceeds the size limit it needs to be replaced.

Clutch cover check

Pressure plate check

Examination of the pressure plate aims to determine the condition of the surface on the pressure plate.

It could be that the pressure plate is uneven, causing the clutch to vibrate, for a standard gap size of 0.5 mm by placing a straight axle and pressing it then inserting a 0.5 mm feeler gauge.

Pressure plate check

Clutch disc check and repair

This examination aims to determine the thickness of the coupling lining, measure the rivet depth using a compass shove with a minimum size of 0.3 mm, if less than that then need to be replaced.

Also check visually for burn marks and grease or oil on the surface of the clutch plate.

Clutch disc check

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Replacing and Installing the Clutch

Before all components are installed, lubricate the relief bearing and transmission shaft first using grease.

Then install the clutch lining and clutch housing on the flywheel.

By using the center clutch to make it easier later when installing the transmission shaft.

After one clutch housing is installed, then install the housing fixing bolts clutch which amounts to 8 using a 12 mm socket wrench evenly and alternately.

After all the bolts are installed then tighten using a wrench moment.

Installation of pressure plate unit and clutch housing Place the pressure plate on the pressure plate holder. Install the pressure spring in its holder on the pressure plate.

Install the clutch cover behind the pressure spring in the correct position
appropriate. Install the pressure lever on the seat on the clutch cover.

Press the clutch cover with a pressure tool so that the pressure spring is compressed so that the grip bolt / pressure lever adjuster can be installed.

Release the pressure of the pressing machine, and make the pressure height adjustment

Clutch unit installation

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After the clutch cover unit is installed, the installation of the clutch lining and clutch unit can be done.

Apply a little special grease to the clutch hub groove. Insert the clutch canter on the clutch hub and adjust the position of the clutch plate.

Attach the clutch plate to the fly wheel with the canter guide and adjust its position so that it is right in the middle.

Install the clutch cover unit by paying attention to the marks we made on the disassembly and the accuracy of the knock pins. Install the clutch cover fixing bolts.

Manual Clutch System Repair

Do the hardening of the fastening bolts gradually. Get started hardening of the bolt closest to the knock pin cross.

Before tightening the bolts, make sure again the position of the clutch plate by adjusting the position of the clutch canter.

Tighten the fastening bolts according to the specified tightening moment, which is around 195 kg cm or 19 N-m.

After the clutch unit is installed properly, install the release lever, shift release lever and release bearing on the seat by applying a little special grease / grease to some of the friction parts.

Make sure that the release fork locks against the axle and the release bearings against the release fork are securely attached.

After all components of the clutch unit are installed, assemble / install the transmission unit.

Transmission shift unit, propeller (FR and FWD type vehicles) and release cylinder.

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