Garage411 : ClutchS2k

Revision [3784]

Last edited on 2009-07-12 16:07:28 by Spartanic23 [revised]
Deletions:
{{source4}}

Revision [3435]

Edited on 2009-07-06 17:53:54 by Spartanic23 [revised]
Additions:
=====''Honda S2000 Clutch''=====
{{sourcebigbox2}}
{{sourcebigbox2}}
Deletions:
>>{{source1}}>> =====''Honda S2000 Clutch''=====

Revision [3156]

Edited on 2009-06-20 13:04:50 by Spartanic23 [revised]
Additions:
>>{{source1}}>> =====''Honda S2000 Clutch''=====
[[HondaS2000 Honda S2000 AP1]]
{{linkunit2}}
Deletions:
=====''Honda S2000 Clutch''=====

Revision [2830]

Edited on 2009-06-16 18:23:16 by FreeMan [revised]

No differences.

Revision [2829]

Edited on 2009-06-16 17:11:48 by FreeMan [revised]
Additions:
3. Pull back the boot, and apply brake assembly lube or equivalent rubber grease to the boot and slave cylinder rod. Reinstall the boot. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch12.gif See figure]].
Deletions:
3. Pull back the boot, and apply brake assembly lube or equivalent rubber grease to the boot and slave cylinder rod. Reinstall the boot. [http://www.garage411.com/images/Honda/Ap1/tranny/clutch12.gif See figure]].

Revision [2828]

Edited on 2009-06-16 17:10:33 by FreeMan [revised]
Additions:
===''DELAY ORIFICE MECHANISM - Honda S2000 2004 MODEL''===
The delay orifice mechanism improves clutch operation by delaying the slave [[CylinderHeadS2k cylinder]] release speed when the clutch pedal is suddenly released. The delay orifice mechanism is built into the slave cylinder. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch3.gif See Figure]].
===''CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT''===
1. Loosen the locknut, and back off the clutch switch until it no longer touches the clutch pedal. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch6.gif See Figure]].
2. Loosen the locknut, and turn the pushrod in or out to get the specified height and stroke at the clutch pedal.
3. Tighten the locknut .
4. With the clutch pedal released, turn in the clutch pedal position switch until it contacts the clutch pedal.
5. Turn in the clutch pedal position switc an additional 3/4 to 1 turn.
6. Tighten the locknut.
7. Loosen the locknut and the clutch interlock switch.
9. Release the clutch pedal 15-20 mm (0.59-0.79 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch so the engine will start with the clutch pedal in this position.
10. Tighten the locknut.
===''CLUTCH MASTER CYLINDER REPLACEMENT''===
1. The brake fluid may be sucked out through the top of the master cylinder reservo with a syringe. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch7.gif See figure]].
2. Disconnect the clutch line from the clutch master cylinder. Plug the end of the clutch line and reservoir hose with a shop towel to prevent brake fluid from coming out.
3. Pry out the lock pin, and pull the pedal p out of the yoke. Remove the master cylinder mounting nuts. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch8.gif See figure]].
4. Remove the clutch master cylinder. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch9.gif See figure]].
===''SLAVE CYLINDER REPLACEMENT''===
1. Remove the banjo bolt and washers, then disconnect the clutch hose from the slave cylinder. Plug the end of the clutch hose with a shop towel to prevent brake fluid from coming out. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch10.gif See figure for S2000 2000-2003 model]]. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch11.gif See figure for S2000 2004 model]].
2. Remove the two bolts and slave cylinder.
3. Pull back the boot, and apply brake assembly lube or equivalent rubber grease to the boot and slave cylinder rod. Reinstall the boot. [http://www.garage411.com/images/Honda/Ap1/tranny/clutch12.gif See figure]].
4. Apply super high temp urea grease (PN 08798-9002) to the tip of the slave cylinder rod.
~-Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
7. Make sure the fluid level in the reservoir is at the MAX (upper) level line. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch17.gif See figure]].
>>{{image url="http://www.garage411.com/images/Honda/Ap1/misc/sachs_clutch.jpg" title="text" alt="text"}}>> ===''CLUTCH REPLACEMENT''===
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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch18.gif 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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch20.gif See figure]].
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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch21.gif See figure]].
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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch24.gif See figure 1 of 2]]. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch25.gif See figure 2 of 2]].
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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch26.gif See figure]].
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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch27.gif See figure]].
3. Remove the ball bearing from the flywheel. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch29.gif See figure]].
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.
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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch34.gif See figure]].
5. Install the pressure plate and the mounting bolts, finger-tight. Make sure the release bearing does not come off.
**Did you find this repair info helpful or are improvements needed? Please leave comments below.**
Deletions:
==''DELAY ORIFICE MECHANISM - Honda S2000 2004 MODEL''==
The delay orifice mechanism improves clutch operation by delaying the slave cylinder release speed when the clutch pedal is suddenly released. The delay orifice mechanism is built into the slave cylinder. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch3.gif See Figure]].
==''CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT''==
1. Loosen the locknut (A), and back off the clutch switch (B) until it no longer touches the clutch pedal (C). [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch6.gif See Figure]].
2. Loosen the locknut (D), and turn the pushrod (E) in or out to get the specified height (F) and stroke (G) at the clutch pedal.
3. Tighten the locknut (D).
4. With the clutch pedal released, turn in the clutch pedal position switch (B) until it contacts the clutch pedal (C).
5. Turn in the clutch pedal position switch (B) an additional 3/4 to 1 turn.
6. Tighten the locknut (A).
7. Loosen the locknut (H) and the clutch interlock switch (I).
9. Release the clutch pedal 15-20 mm (0.59-0.79 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch (I) so the engine will start with the clutch pedal in this position.
10. Tighten the locknut (H).
==''CLUTCH MASTER CYLINDER REPLACEMENT''==
1. The brake fluid may be sucked out through the top of the master cylinder reservoir (A) with a syringe. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch7.gif See figure]].
2. Disconnect the clutch line (B) from the clutch master cylinder. Plug the end of the clutch line and reservoir hose with a shop towel to prevent brake fluid from coming out.
3. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke. Remove the master cylinder mounting nuts (C). [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch8.gif See figure]].
4. Remove the clutch master cylinder (A). [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch9.gif See figure]].
==''SLAVE CYLINDER REPLACEMENT''==
1. Remove the banjo bolt (A) and washers (B), then disconnect the clutch hose (C) from the slave cylinder (D). Plug the end of the clutch hose with a shop towel to prevent brake fluid from coming out. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch10.gif See figure for S2000 2000-2003 model]]. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch11.gif See figure for S2000 2004 model]].
2. Remove the two bolts (E) and slave cylinder.
3. Pull back the boot (A), and apply brake assembly lube or equivalent rubber grease to the boot and slave cylinder rod (B). Reinstall the boot. [http://www.garage411.com/images/Honda/Ap1/tranny/clutch12.gif See figure]].
4. Apply super high temp urea grease (P/N 08798-9002) to the tip of the slave cylinder rod.
~-Attach a hose to the bleeder screw (A), and suspend the hose in a container of brake fluid.
7. Make sure the fluid level in the reservoir is at the MAX (upper) level line (A). [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch17.gif See figure]].
>>{{image url="http://www.garage411.com/images/Honda/Ap1/misc/sachs_clutch.jpg" title="text" alt="text"}}>> ====''CLUTCH REPLACEMENT''====
1. Check the height-variation of the diaphragm spring fingers using the dial indicator (A). If the variation is more than the service limit, replace the pressure plate. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch18.gif See figure]].
3. To prevent warping, unscrew the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B).
4. Remove the release bearing (C) from the pressure plate.
5. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch20.gif See figure]].
7. Inspect for warpage using a straight edge (A) and feeler gauge (B). Measure across the pressure plate (C). If the warpage is more than the service limit, replace the pressure plate. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch21.gif See figure]].
11. Measure the rivet depth from the clutch disc lining surface (A) to the rivets (B), on both sides. If the rivet depth is less than the service limit, replace the clutch disc. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch24.gif See figure 1 of 2]]. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch25.gif See figure 2 of 2]].
3. Measure the flywheel (A) runout using a dial indicator (B) 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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch26.gif See figure]].
4. Turn the inner race of the ball bearing (A) 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. [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch27.gif See figure]].
3. Remove the ball bearing (A) from the flywheel (B). [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch29.gif See figure]].
1. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Slide the clutch disc onto the mainshaft, and remove extra overflow grease.
4. Apply super high temp urea grease (P/N 08798-9002) into the groove (A) of the release bearing (B), then install the release bearing on the pressure plate (C). [[http://www.garage411.com/images/Honda/Ap1/tranny/clutch34.gif See figure]].
5. Install the pressure plate and the mounting bolts (D), finger-tight. Make sure the release bearing does not come off.

Revision [1823]

Edited on 2009-05-12 14:40:35 by MasterBlaster
Additions:
>>{{image url="http://www.garage411.com/images/Honda/Ap1/misc/sachs_clutch.jpg" title="text" alt="text"}}>> ====''CLUTCH REPLACEMENT''====
Deletions:
>>{{image url="http://www.garage411.com/images/Honda/Ap1/misc/sachs_clutch.jpg" title="text" alt="text"}}
{{sourcebigbox}}>> ====''CLUTCH REPLACEMENT''====

Revision [1822]

Edited on 2009-05-12 14:39:41 by MasterBlaster
Additions:
>>{{image url="http://www.garage411.com/images/Honda/Ap1/misc/sachs_clutch.jpg" title="text" alt="text"}}
{{sourcebigbox}}>> ====''CLUTCH REPLACEMENT''====
Deletions:
>>{{source1}}>> ====''CLUTCH REPLACEMENT''====

Revision [1681]

Edited on 2009-05-07 22:48:55 by Spartanic23 [refined]
Additions:
>>{{source1}}>> ====''CLUTCH REPLACEMENT''====
Deletions:
>>{{sourcebigbox}}>> ====''CLUTCH REPLACEMENT''====

Revision [1496]

Edited on 2009-05-01 23:28:17 by Spartanic23
Additions:
~-Check the clutch pedal position switch.
>>{{sourcebigbox}}>> ====''CLUTCH REPLACEMENT''====
Deletions:
~-Check the clutch pedal position switch. >>{{source2}}>>
>>{{sourceslim}}>> ====''CLUTCH REPLACEMENT''====

Revision [1319]

Edited on 2009-04-30 18:04:47 by Spartanic23
Additions:
>>{{sourceslim}}>> ====''CLUTCH REPLACEMENT''====
Deletions:
====''CLUTCH REPLACEMENT''====

Revision [1058]

Edited on 2009-04-27 19:15:46 by Spartanic23
Additions:
1. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Slide the clutch disc onto the mainshaft, and remove extra overflow grease.
{{source4}}
Deletions:
1. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Slide the clutch disc onto the mainshaft, and remove extra overflow grease. >>{{source2}}>>

Revision [1036]

Edited on 2009-04-27 18:29:52 by Spartanic23
Additions:
==''Clutch Disc and Pressure Plate Installation''==
1. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Slide the clutch disc onto the mainshaft, and remove extra overflow grease. >>{{source2}}>>
Deletions:
==''Clutch Disc and Pressure Plate Installation''==
1. Apply a thin, uniform coat of super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B). Slide the clutch disc onto the mainshaft, and remove extra overflow grease.

Revision [1035]

Edited on 2009-04-27 18:28:34 by Spartanic23 [Reverting last edit by Spartanic23 [1034] to previous version [1033]]
Additions:
==''CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT''==
==''CLUTCH MASTER CYLINDER REPLACEMENT''==
==''SLAVE CYLINDER REPLACEMENT''==
====''CLUTCH REPLACEMENT''====
==''Pressure Plate and Clutch Disc Removal''==
==''Flywheel Inspection''==
==''Flywheel Replacement''==
==''Release Bearing Inspection''==
==''Clutch Disc and Pressure Plate Installation''==
Deletions:
==''Honda S2000 CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT''==
==''Honda S2000 CLUTCH MASTER CYLINDER REPLACEMENT''==
==''Honda S2000 SLAVE CYLINDER REPLACEMENT''==
====''Honda S2000 CLUTCH REPLACEMENT''====
==''Honda S2000 Pressure Plate and Clutch Disc Removal''==
==''Honda S2000 Flywheel Inspection''==
==''Honda S2000 Flywheel Replacement''==
==''Honda S2000 Release Bearing Inspection''==
==''Honda S2000 Clutch Disc and Pressure Plate Installation''==

Revision [1034]

Edited on 2009-04-27 18:27:28 by Spartanic23
Additions:
==''Honda S2000 CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT''==
==''Honda S2000 CLUTCH MASTER CYLINDER REPLACEMENT''==
==''Honda S2000 SLAVE CYLINDER REPLACEMENT''==
====''Honda S2000 CLUTCH REPLACEMENT''====
==''Honda S2000 Pressure Plate and Clutch Disc Removal''==
==''Honda S2000 Flywheel Inspection''==
==''Honda S2000 Flywheel Replacement''==
==''Honda S2000 Release Bearing Inspection''==
==''Honda S2000 Clutch Disc and Pressure Plate Installation''==
Deletions:
==''CLUTCH PEDAL, CLUTCH PEDAL POSITION SWITCH, AND CLUTCH INTERLOCK SWITCH ADJUSTMENT''==
==''CLUTCH MASTER CYLINDER REPLACEMENT''==
==''SLAVE CYLINDER REPLACEMENT''==
====''CLUTCH REPLACEMENT''====
==''Pressure Plate and Clutch Disc Removal''==
==''Flywheel Inspection''==
==''Flywheel Replacement''==
==''Release Bearing Inspection''==
==''Clutch Disc and Pressure Plate Installation''==

Revision [1033]

Edited on 2009-04-27 18:25:09 by Spartanic23
Deletions:
{{source4}}

Revision [1032]

Edited on 2009-04-27 18:20:47 by Spartanic23
Additions:
{{source4}}

Revision [1031]

Edited on 2009-04-27 18:16:34 by Spartanic23
Additions:
~-Check the clutch pedal position switch. >>{{source2}}>>
Deletions:
~-Check the clutch pedal position switch.

Revision [662]

Edited on 2009-04-01 19:39:54 by MasterBlaster

No differences.

Revision [661]

The oldest known version of this page was created on 2009-04-01 19:38:32 by MasterBlaster
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