0435605 EVINRUDE DECAL SET, Jo.

The clutch is a dry single disc type which connects and disconnects engine power through the clutch shift shaft.When the operation for clutch disengagement is done, the clutch release lever is pushed. Since the clutch release lever pivots about the release lever pin in the release lever support provided in the clutch cover, the pressure spring is compressed, causing the clutch disc clamped between the engine flywheel and pressure plate to become free and cut power transmission. When the operation for clutch engagement is done, the pressure spring force causes the pressure plate to press the clutch disc against the engine flywheel to transmit power.The clutch consists of a clutch disc, pressure plate and release lever. The clutch disc has a woven facing.2. Specifications
(1) Clutch (2) Bearing case 3. Service Standards
3.1 Service Standards Table
3.2 Tightening torque table
4. Special Tool
5. Service Procedures
5.1 Removal and Installation
(1) Removal (a) When removing the pressure plate and lever assembly, fix the pressure plate using the special tools, Stopper Bolt and Washer. (C4 and C8 only) (b) Install the special tool, Clutch Alignment Arbor to prevent drop of the clutch disc and then remove the pressure plate and lever assembly.(2) Installation (a) Install the clutch disc using the special tool, Clutch Alignment Arbor. When installing the clutch disc, use care not to confuse the front and reverse sides. Install with the side bearing the part No. facing outside. (b) Install the pressure plate and lever assembly, aligning with the knock pins of the fly wheel. In the case of C4 and C8, install after fixing the pressure plate using special tools, Stopper Bolt and Washer. 1. Before installing the clutch, check and clean the flywheel. If faulty, correct or replace.2. When tightening the bolts, do so in diagonal order and uniformly.3. After installation, be sure to remove the Stopper Bolt and Washer. (C4 and C8 only)(c) Inspection of release lever plate height (at clutch disc replacement only) Using special tool, Clutch Release Lever Aligner, check the height of the clutch cover and release lever plate.If adjustment is necessary, adjust referring to 5.2.2 (3).(d) Adjustment after installation of bearing case. After installation, adjust the free travel (clearance between the release bearing and release lever). 1) Move the lever in the direction to engage the clutch. At a position where a click is heard in the clutch, turn the adjusting bolt A until it is blocked by the stopper, and lock it by turning down the bolt another two or three threads.2) From the position where the release bearing has touched the release lever, turn the adjusting screw B in the direction to disengage the clutch and check to see that the clutch is in disengaged position. Then lock the bolt. When making adjustment, lock in position the ratchet of the lever of the opposite side. 1) Loosen the control ling lock nut and from the position where the release bearing is in contact with the release lever, move back by B1 mm and lock in position (clutch lever setting position when clutch is engaged).2) In the direction to disengage the clutch, lock the air cylinder adjusting bolt at a position B2 mm from the position where the release bearing is in contact with the release lever.5.2 Clutch Proper
Disassembly and inspection
Disassembly and Inspection(1) Removal of clutch cover (a) Matchmark the clutch cover and pressure plate and using special tool, Clutch Installer, compress the pressure spring and remove support lever nut, strap bolt, etc.(b) Slowly loosen the handle of the Clutch Installer to remove the clutch cover.(2) Wear of facing Measure the depth from facing surface to rivet head. If the depth is smaller than the limit, replace the clutch disc assembly.(3) Runout of clutch disc Using a runout tester, measure the runout of the clutch disc. If it exceeds the limit, correct or replace.(4) Spline play in turning direction Using a piano wire, etc., measure the play in turning direction of the clutch disc boss splines and transmission drive pinion splines. If it exceeds the limit, replace the clutch disc.(5) Thickness of pressure plate Measure the thickness of the pressure plate. If it is smaller than the limit, replace.(6) Flatness of pressure plate Measure the flatness of the pressure plate friction surface. If it exceeds the limit, correct by polishing or replace.(7) I.D. of strap bolt fitting hole Measure I.D. of the strap bolt fitting hole. If it exceeds the limit, replace.(8) Clearance between release lever pin and bushing Measure O.D. of the release lever pin and I.D. of the bushing to calculate the clearance. If it exceeds the limit, replace.(9) Clearance between support lever pin and bushing Measure O.D. of the support lever pin and I.D. of the bushing to calculate the clearance. If it exceeds the limit, replace.(10) Inspection of pressure spring Measure squareness and free length of the pressure spring. If out of specification, replace the pressure spring.Reassembly
Reassembly (1) If the friction surface of the pressure plate was corrected, insert an adjusting washer corresponding to ground-away dimension. (2) Installation of clutch cover Use special tool, Clutch Installer to install the clutch cover. Install the clutch cover and pressure plate aligning the match marks that have been put.(3) Adjustment of release lever height To adjust the release lever height, compress the pressure spring using the Clutch Installer and adjust the support lever nut so that the end of the release lever plate is positioned at specified distance from the flywheel friction surface. Then, temporarily lock with the lock bolt.For final adjustment of release lever height after replacement of the clutch disc, use special tool, Clutch Release Lever Aligner with the clutch installed to the engine flywheel. (Refer to Item (c), Section 5.1.) Adjust the release lever height only when the clutch disc is new.5.3 Bearing Case
Disassembly and inspection