Installation Instruction
Contents
1. The bolts have to be tightened at the specified tordue The mating surfaces should be cleaned wiped with a clean towel to remove any foreign waste hey may affect the performance of the clutch The bolts are the very important parts Use either genuine Darts or the Dolts Iincluded as auxiliary Darts in the box Do not reuse the old bolts after un tightenin9 12 For further information BC EXEDY Corporation Sports BC 572 0822 1 1 1 1 1 1 Kidamotomiya Neyagawa shi Osaka 572 0822 Japan TEL 072 822 1246 FAX 072 821 6541 E mail sbc exedy co jp Exedy Globalparts Corporation 8601 Haggerty Road South Belleville MI 48111 TEL 800 3462. We recommend replacing the flywheel mounting Dolts to new for all vehicles For the vehicle not shown in the table abDove use the bolts enclosed in the box with product 3 We recommend replacing the pilot Dearing to new even there IS no description in this instruction If the vehicle has It HUS 6 Installation procedure 1 Disassembly of the kit Loosen the bolt No 4 and disassemble the kit 2 Installation of pilot bearing 6 7 Replace the pilot bearing to new genuine one If the Vehicle have It Refer to the list in page 6 4
3. Assy Set up the center bar Pilot tool to the pilot at engine side and center the clutch disc No 2 Tighten the clutch cover Assy No 1 The genuine main drive shaft Input shatt is recommended for this proceSS T M CAUTION Fallure In centering of the clutch disc No 2 may cause the difficulty of installing the transmission and damage the disc causing misalignment CTT 27 29Nm 2 8 3 0kgm 23ft lbs SDecified torque of bolt No 4 Uneven bolt tightening wlll cause diSengagement proDlems and judder Shudder HUS 5 7
4. Do not change any release control function of the vehicle except for the SDeclfied DOSItiOnS The clutch is used under stock condition Especially DO NOT remove the spring in the clutch operator Otherwise the preload working on the release bearing will be lost leading to release of the bearing during usage for the pull type 5 WARNING This clutch system is designed specially for racing DurposeS therefore pedal effort is slightly heavier and operation engaging IS more difficult tnan 9enuine stock clutch StOD using If you are not completely confident with your driving technigue and physical strength HUS 10 6 MT PA 8 3 Advice The
5. Installation work has to be done by a professional installer who is knowledgeable and experienced with the products 3 We will not have any responsibility if the product are used wrongfully or modified 4 We will not accept any claim nor return as this product is used Dredominately for racing and Specification may change without prior notice 5 Please save this instruction after installation For safety Please note the following as these are important warnings and cautions for customers 2 ee WARNING
6. Stroking adjustment After installing this kit the pedal position en9a9ement or disengagement Doint may change Adjust the pedal accordind to the maintenance manual issued by the vehicle manufacturer Advice e lf the pedal position should be moved towards the floor adjust the push rod of the master cylinder In the manner the pedal height is down in free position lf the pedal position should be moved away from the floor adjust the Dush rod in the opposite to the above HUS NE Caution during operation 1 400 500mile ALTT After installation drive carefully and gently Iravel for approximately 40
7. 3 Confirm that lever height is egual after tightening lf it is not equal then restart from procedure 3 8 T M Install the Iransmission IM Purchase a new release Dearing and apply grease to sliding Surface Follow the maintenance manual issued by the vehicle manufacturer T M SATION Do not hit the spline teeth with the tip edge of the main drive shatt lt will cause disen9a9ement problems or damage to the clutch disc Donot hang tne transmission using the dls 9
8. F W Installation of flywheel F W 1 6 7 FW Make sure to use the crank bolt flywheel mounting bolt specified in the list in page 6 7 when Iinstall the flywheel No 3 Note 1 For GHO2SD 53Nm 39Lbs ft Tighten the bolts at 53Nm 39Lbs ft as a first pass as shown in the below drawing Mark at the top pf tne bolt heads with a color paint for marking 25 Tighten the crank bolts 25 degree furtner relative to the paint mark as a final pass Check the paint mark located on the right side HUS 5 AssemDly of Darts Assy NO
9. Ignoring this warnindg may cause death or extreme InjUry CAUTION Ignoring this caution may cause injury or damage CTT HUS _ Caution during handling 1 ALTT 2 MM 3 i 4 I Handle carefully since this product is heavy C BRG NEVER hold the inner diameter of the diaphragm spring If it is pull type Otherwise the color or C ring may be damaged then cause the release Dearin9 DODDIn9 out Do not place the product on the floor directly as this may cause rust to apDDear On the product Do not throw or drop the product as it IS a pr
10. Save this instruction Installation Instruction EXEDY RACING CLUTCH Thank you very much for your Durchase of EXEDY RACING CLUTCH Be sure to read this installation manual prior to install this product Please save tnis manual carefully while the product IS In use EXEDY EXEDY Corporation 2006 08 25 lssued on May 25 2006 SBC lssued by EXEDY Corporation Sports BC HUS Installation instruction introduction This installation instruction includes useful and important information to prevent proDblems from occurring during installation 1 Please read through this instruction before installation 2
11. 0 500miles in a city area lf the clutch is used in a condition where the friction surface is not contacting fully with tne mating surface It will cause slip Durnind udder Shudder or short life 2 Ms It iS recommended to re adjust the stroke after the break in Deriod Due to the nature of clutch for racing DurposeS half engaged clutch operation will also be affected after break In Deriod Dut this is a normal symptom 3 It iS not abnormal if subtle noise or chattering occurs depending on the operating conditions when engading the clutch 4 et WARNING lt
12. 6091 FAX 734 397 7300 E mail techsupport exedyusa com EXEDY AUSTRALIA PTYLTD 21 Five ways Boulevard Keys borough Victoria 3173 AUSTRALIA TEL 61 3 9701 5556 _ FAX 61 3 9701 5684 EXEDY Clutch Europe Ltd Unit 2 Rokeby Court Manor Park Runcom Cheshire WA7 1RW UK TEL 44 1928 571850 FAX 44 1928 571852 HUS ie
13. Assembly order gt Clutch disc gt Clutch cover Assy Make sure to match the blue paint marks on the outer diameter for positioning of the 1 Clutch Cover and 3 Flywheel CAUTION EXEDY Be careful of the direction location of the clutch disc to locate EXEDY logo needs to be seen from the cover side Put the logo side toward Clutch cover transmission 4 3 CAUTION lf the markings are not matched it may cause noise and vibration issue may reduce the engine output CAUTION Apply grease Speclfied by the vehicle manufacturer to the spline hub tnen insert the input shaft and wipe away any excessive grease On the shaft and hub 6
14. ecision Dart Caution during installation WARNING 2 WARNING 9 WARNING 4 WARNING 5 WARNING HUS i Ask a licensed shop dealer for installation Install the product according to the maintenance manual of the vehicle and this InStructiOn Do not apply this product to vehicles other than specified by EXEDY Do not modify or disassemble this product unless otherwise specified In this instruction lf a failure such as abnormal noise vibration odor or disengagement problem occurs during driving stop the vehicle immediatel
15. life of a clutch may be adversely affected by driving technidue and driving COnditionS Especlally the friction material is worn prematurely in a racing which necessitates freduent abrupt start operation for example drag race Check it freduently Record the new release fork position and confirm its variation Facing wear amount can then be foreseeaDple Preventative maintenance before the discs are worn out is a key factor to maintain steady Derformance Maximum facing wear Facing tnickness 3 6mm 4 6mm 3 6 mm At new 4 6 mm WARNING lf the clutch is used in the half engaged position for extended periods of time the clutch set will generate high temperatures This high heat creates expanslon Or deformation which may cause disengademen
16. t proDblems temporarily or permanently Stop driving and allow the clutch to cool down WARNING Do not over use the clutch beyond the following limits Operation limit list gt Item Limitation 460 Nm 47 kgm Max engine torque 345 Lbs ft 92N20 9 10000 mim Max engine rpm 800 C Max friction surface temperature EE RR A A 9 0 mm 8 0 mm Max release stroke HUS i 9 10 11 HUS WARNING WARNING WARNING Do not machine modify any part of this product otherwise the strength of each Dart will be reduced and may fall prematurely
17. y and have a licensed garage Inspect the vehicle Applicable vehicle and model ApplicaDble vehicle model Manufacturer Part No Clutch size Vehicle model Endine model GHO2SD 6225 SAN 2 0L DOHC Ecotec lon Redline SUDer Charged HUS 5 Components and structural drawing NO NO Description Number of pieces Assy CCA Clutch cover Assy CCA CDA Clutch disc Assy CDA F WV Flywheel F W Bolt Washer Flywheel mounting bolt Crank bolt se page 6 7 HUS ie Manufacturer Vehicle model Engine model Parts No Parts reduired to be prepared Flywheel mounting bol Genuine Darts Release bearing Genuine parts GHO02SD Ecotec lon Redline Super Charged 3 Advice 1 We recommend replacing the release Dearing to new for all vehicles 2
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