Honda S2000 Clutch & Flywheel Removal

by NinjaX on July 1, 2010

Honda S2000 clutch removal applies to 1999-2003 models.

SPECIAL TOOLS NEEDED

  • Clutch alignment shaft 07LAF-PT00110
  • Remover handle 07936-3710100
  • Ring gear holder 07LAB-PV00100 or 07924-PD20003
  • Driver 07749-0010000
  • Attachment, 32 x 37 mm 07746-0010200

Pressure Plate and Clutch Disc Removal

1. Check the height-variation of the diaphragm spring fingers using the dial indicator. If the variation is more than the service limit, replace the pressure plate. See figure.

  • Standard (New): 0.4 mm (0.016 in.) max.
  • Service Limit: 0.6 mm (0.024 in.)

2. Install the special tools. See figure.
3. To prevent warping, unscrew the pressure plate mounting bolts in a crisscross pattern in several steps, then remove the pressure plate.
4. Remove the release bearing from the pressure plate.
5. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area. See figure.
6. Inspect the surface of the pressure plate for wear, cracks, and burning.
7. Inspect for warpage using a straight edge and feeler gauge. Measure across the pressure plate. If the warpage is more than the service limit, replace the pressure plate. See figure.

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

8. Remove the clutch disc and special tools. See figure.
9. 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.
10. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. See figure.

  • Standard (New): 8.2-8.9 mm (0.32-0.35 in.)
  • Service Limit: 6.0 mm (0.24 in.)

11. Measure the rivet depth from the clutch disc lining surface to the rivets, on both sides. If the rivet depth is less than the service limit, replace the clutch disc. See figure 1 of 2. See figure 2 of 2.

  • Standard (New): 1.2-1.7 mm (0.047-0.067 in.)
  • Service Limit: 0.2 mm (0.008 in.)

Flywheel Inspection

1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
3. Measure the flywheel runout using a dial indicator 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. See figure.

  • Standard (New): 0.05 mm (0.002 in.) max.
  • Service Limit: 0.15 mm (0.24 in.)

4. Turn the inner race of the ball bearing with your finger. The ball bearing should turn smoothly and quietly. Check that the ball bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the ball bearing. See figure.

Flywheel Replacement

  1. Install the special tool. See figure.
  2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.
  3. Remove the ball bearing from the flywheel. See figure.
  4. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface. See figure.
  5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and mounting bolts, finger-tight.
  6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. See figure.

Release Bearing Inspection

Check the play of the release bearing by spinning it with your hand, if there is excessive play, replace the release bearing with a new one. See figure.

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

Clutch Disc and Pressure Plate Installation

  1. Apply a thin, uniform coat of super high temp urea grease (PN 08798-9002) to the splines of the clutch disc. Slide the clutch disc onto the mainshaft, and remove extra overflow grease.
  2. Install the ring gear holder. See figure.
  3. Install the clutch disc using the special tools.
  4. Apply super high temp urea grease (PN 08798-9002) into the groove of the release bearing, then install the release bearing on the pressure plate. See figure.
  5. Install the pressure plate and the mounting bolts, finger-tight. Make sure the release bearing does not come off.
  6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. See figure.
    • PRESSURE PLATE MOUNTING BOLT TORQUE: 25 N.m (2.6 kgf.m, 19 lbf.ft)
  7. Remove the special tools.
  8. Make sure the diaphragm spring fingers are all the same height.

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