取扱説明書 Installation manual
Contents
1. The bolts are the very important parts Use either genuine parts or the bolts included as auxiliary parts in the box Do not reuse the old bolts after un tightening For further information 0000 EXEDY Corporation Sports 0 572 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 USA 8601 Haggerty Road South Belleville MI 48111 TEL 800 346 6091 FAX 734 397 7300 E mail EXEDY AUSTRALIA PTY LTD 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 M300 192. Please do not use the product wrongfully nor modify the parts In such case we will not take any responsibility 4 We will not accept any claim nor return as this product is used predominately for racing and specification may change without prior notice 5 Please keep this manual following installation aooi For safety Please note the following as these are important warnings and cautions for our customers WARNING CAUTION Lr e ou 3 25 2 og nn S 5 3 3 lt ause death or extreme injury this caution may cause injury or damage L LI orin M300 2 000000000 Caution during handling 1 CAUTION 2 CAUTION 3 CAUTION 4 CAUTION
3. The life of a metal multiple disc clutch may be adversely affected by driving technique and driving conditions Especially the friction material is worn prematurely in a racing which necessitates frequent abrupt start operation for example drag race Check it frequently ugnnugnu ugnanugnpuupnpuuanpaugauggnanugpnpugapnpu udnaudu Record the new release fork position and confirm its variation Facing wear amount can then be foreseeable Preventative maintenance before the discs are worn out is a key factor to maintain steady performance Maximum facing wear Facing thickness 8 WARNING M300 200 LL E 9 0 mmt ELEL l 4 0 9200 Series 3 0 mm At new 4 0 mm Due to the nature of the multiple disc clutch if 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 expansion or deformation which causes disengagement problems temporarily or permanently Stop driving and allow the clutch to cool down warung
4. Do not over use the clutch beyond the following limits 9 M300 17 Operation limit list Limit 10 11 12 M300 Max engine rpm 12000 r mim Max engine torque 000 Ton 830 Nm 85 kgm 1230 Nm 125 1470 Nm 150 20mm Max disc wear Total 2 0 mm 800 Max friction surface temperature 9 0 mm Max release stroke WARNING WARNING WARNING 000 Do not machine any part of this product otherwise the strength of each will be reduced and may fail prematurely The bolts have to be tightened at the specified torque The mating surfaces should be cleaned wiped with a clean towel to remove any foreign waste They may affect the performance of the clutch
5. 0 0 0 S s ETE Ed EI L3 L3 C3 C3 SI 0000000000000000000000000000000000000 caunoN Do not hit the spline teeth with the edge of the main drive shaft It will cause disengagement problems or damage to the clutch disc 8 0000000 Stroking adjustment After installing of this kit the pedal position engagement or disengagement point may change Adjust the pedal according to the maintenance manual issued by the vehicle manufacturer M300 13 Advice PT I e pedal position should be moved towards the floor adjust the push rod of the master cylinder he manner the pedal height is down in free position If the pedal position should be moved away from the floor adjust the push rod in
6. Number of pieces No Description Pull type Push type Assy 1 Clutch cover Assy CCA O0000000000 PP Pressure plate PP 000000000 000 100000 2 Center plate IMP Twin 1 Triple 2 1 1 Clutch disc A 00000000 B CDB 1 1 Clutch disc B CDB 00000000 e cpo 1 Clutch disc Triple 1 1 Flywheel ring FWR e Bn n nnnFwg i Flywheel F W 000A Bolt A Bolt B Washer 15 00 Hun 1 E Pivot ring n 7008000 Flywheel mounting bolt Crank bolt See page 7 M300 5 M300 6 Parts required additionally 0000 0000 Manufacturer Vehicle model Engine model Parts No Parts required to be prepared NM012SD 000000000 0000 30502 14601 913 814 SR20DET NM013SR Release bearing Nissan genuine parts 0000 30502 14601 NM022SD Release bearing Nissan genuine parts Bi 200 2 35 8 000000000 32202 89500 Pilot bush Nissan genuine parts 03250 NMOS33SR E IL NISSAN BNR32 RB2
7. As this product is heavy handle carefully when removing it from the box As for the pull type NEVER hold the inner diameter of the diaphragm Otherwise the color or C ring may be deformed leading to release of the bearing Do not place the product on the floor directly as this may cause rust to appear on the product Do not throw or drop the product as it is a precision part Caution during installation 1 WARNING 2 WARNING 3 WARNING 4 WARNING 5 WARNING M300 Use a licensed installer as the transmission unit is to be taken out of the vehicle Install the product according to the maintenance manual of the vehicle and this installation manual Do not apply this product to vehicles other than those specified EXEDY Do not modify this product unless inst
8. Manufacturer Engine model Tightening torque SR20DET 830 93 Nm 8 50 9 5 kgm RB26DETT RB25DET NISSAN RB20DET 1420 152 Nm 14 50 15 5 kgm VG30DETT 830 93 Nm 8 50 9 5 kgm I 49 Nm 5 0 kgm 1 TOYOTA 1JZ GTE 2JZ GTE Note 1 000 SUBARU EJ20 690 78 Nm 70 8 MITsUBiSHE 4963 1270 137 Nm 130 14 kgm 000 HONDA C30 32B 103 Nm 10 5 01 000 4052 Note 1 As for the Toyota 1JZ and 2JZ tightening below must be carried out after the crank bolts are tightened with the tightening torque shown in the table above See the drawing below 1 Paint the bolt head with a color paint for marking 2 9000000 Tighten the crank bolt a further 90 degree relative the paint mark 3 Check the paint mark located on the right side M300 10 2 0000 en 7 Mazda vehicle Fix the Mazda genuine counterweight see page 7 to the flywheel No 6 with the supplied special bolts xpDp uapnpuuapnugaugnnuuapnpuuangpaugnugapnpnuapnpudnagadu 540 74 Nm 5 50 7 5 kgm ugnnugnupnpnuuapnpuunguagnnuunpuunpaugnugpgnpnudpnpu
9. 000 Keep this manual A r Installation manual I 0 EXEDY RACING CLUTCH 100 0 Thank you very much for your purchase of EXEDY RACING CLUTCH Be sure to read this installation manual prior to use Please keep this manual carefully while the product is in use EXEDY EXEDY Corporation D DB D 2005 03 18 Issued on March 18 2005 SBC Issued by EXEDY Corporation Sports BC M300 d Installation manual introduction This installation manual includes useful information to prevent problems from occurring during installation 1 ease read through this manual before installation U E3 E 5 stallation work has to be done by professional installer who will use the product safely 3
10. 00000 90011 PR7 000 000 Flywheel mounting bolt HONDA genuine parts NA1 2 0 32B HM012SD m HONDA a Release bearing Genuine parts M300 zu Parts to be prepared other than the above ones 1 140000000000000000000000600 Release bearings shown in page 14 are required for the push type Nissan vehicles 2 We recommend you replace the release bearing for all vehicle models with a new one s gpnaugn unupnugougangpnununupngagagdgpanaunubd We recommend you replace the flywheel mounting bolts for all vehicle models with new ones For the vehicle models not shown in the table above use bolts enclosed with the product 4 As for the vehicle model that no description is provided for the pilot bearing and a bearing is incorporated into the crank we recommend you replace the pilot bearing with a new one at the time of replacement of the clutch 00000 Installation procedure 1 Disassembly
11. Tighten the flywheel mounting bolts diagonally not at a time but for several times with equal force Finally tighten up it with the specified torque Specified torque From 54 to 74 Nm from 5 5 to 7 5 kgm Then install the flywheel to the Eccentric shaft in accordance with the maintenance manual issued by the vehicle manufacturer 5 Assembly of parts gau 0000 0000000000 0000000 50000000 Assy Assembly order Disc C Center plate Disc B Center plate Disc A Pressure plate Pivot ring Clutch cover Assy At the time of assembly be sure to match the painted blue marks on the outer diameter for positioning of the 1 2 3 5 and 6 M300 11 cauron 00000000 AUD SIDED B800 F W SIDED 00000000000 Be careful of the direction location of the disc Twin disc A T M SIDE Twin disc B F W SIDE Triple disc EXEDY mark It should be assembled in such the direction that the identification mark above can be seen from the cover side Triple plate for Supra 1 000000000
12. the opposite to the above 5 rl Release bearing and clutch sleeve for Nissan push type Additionally purchase the release bearing specified by us on page 7 Selection of clutch sleeve Use the clutch sleeve whose sleeve length allows the same inclination of the release fork as that in the case the genuine clutch new one is installed appropriate for each vehicle Nissan vehicle Sleeve enti AU ZK Clutch model Applicable vehicle Recommended sleeve model length 01 514 SR20DET 241 26 mm NM02 S15 SR20DET NM03 R32 RB26DETT 14 16 mm 06 232 VG30DETT 22 24 mm uaBpuanua agnugpnpuapnpa agnadonu Since all the vehicles are individual check the clutches AU and release bearings with installed to them actually Bearing Press in M300 14 Nissan genuine parts number clutch sleeve 30501 A3800 12 mm 30501 50160 22 mm 30501 N1601 14 mm 30501 0H600 24 mm 30501 A0200 18 mm 30501 N1600 28 mm 30501 U0200 1
13. 6 mm 30501 B6000 20 mm 30501 K0510 26 mm 30501 N8400 30 mm pa aanpuanu ugnnuuapnpuanguna ugnnuapnpudnaudu For the pull type vehicles replace the bearing with the genuine new pull type bearing No modification is required 00000000 Caution during operation 1 CAUTION 2 CAUTION 5eokmp 00000 After installation drive carefully and gently Travel for approximately 500 km in a city area If the clutch is used in a condition where the friction surface is not contacting fully with the mating surface it will cause burning judder shudder or short life It is recommended to re adjust the stroke after the break in period Due to the nature of the metal multiple disc clutch half engaged clutch operation will also be affected after break in period but this is a normal symptom In the early stage it is not abnormal if subtle noise or chattering occurs This is due to the characteristics of metal fa
14. 6DETT NMOSSHRW i 2 522 NMO33HRWH ease bearing 9 P NMOSSHRWT 04250 000000 BONIS RB26DETI NM043SR Release bearing Genuine parts NM052SD RB26DETT NM053SR Release bearing Genuine parts SW20 3S GTE TM012SR ooon None uuu JZX90 100 110 00000 90910 02103 TOYOTA 2 70 1204515 TM032SD Flywheel mounting bolt TOYOTA genuine parts TM042SD den anl TMO43SR Release bearing Genuine parts Mazda genuine counterweight 0000 NO 0 200000 0 N327 11 521A ZM012SD 200001 N351 11 521 FC3S 138 ZM013SR Chassis No from 0 to 200000 000 200001 and later MAZDA 000000000 Release bearing Genuine parts N351 11 521 2 0225 Counterweight MAZDA genuine parts FD3S 13B REW MER ZM023SR Release bearing Genuine parts 02250 Flywheel mounting bolt Genuine parts MiTSUBISHI 4063 MMO23SR Release bearing Genuine parts Pilot bearing Genuine parts 8 EJ20 01250 dd 000000000 000000 000 Release bearing Genuine parts SUBARU Dag Pilot bearing Genuine parts GDB EJ20 02250 Release bearing Genuine parts
15. 8 0000 EW II l EWLLD LU Flywheel side disc with stamp of DMO8RA The EXEDY mark should face to the flywheel side The longer center boss of the disc should face to the flywheel 2 00000000 8 Center disc with stamp of DM08RB IIT 0000000100 The EXEDY mark should face to the cover side 3 000000000 bMvoeRA D D D 7 LO C Cover side disc with stamp of DMO8RA III 000000000 The EXEDY mark should face to the cover side The longer center boss of the disc should face to the cover Assemble as shown above CAUTION CAUTION 2 Ez et it will cause unbalance noise and vibration problems Apply grease specified by the vehicle manufacturer to the spline hub then insert the shaft and wipe away any grease which is forced out M300 12 nunugggpununupunupnugonaunpnananuba
16. cings amp Due to the clutch design the multiple disc clutch may cause rattle noise when disengaged This is not an abnormal condition 5 M300 WARNING ununupnugagagpunununugggagngpnananuad Do not change any release control function of the vehicle 6 WARNING 7 CAUTION Advice The clutch is used under normal 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 This clutch system is specially designed for racing purposes therefore pedal effort is slightly heavier and start operation is more difficult than standard manual clutch products Avoid using if you are not completely confident with your driving technique and physical strength ugnuugnugpnpuanuupnpunuunpuapnpna ugguadaonou
17. d Set the centering bar to the engine side pilot Then align the tooth traces of the splines of the discs for centering and tighten the clutch cover Assy No 1 in the structural drawing to fix it The genuine main drive shaft is recommended for this process o0o0000000000000000000007TM00000000000 000000000000000000 If the centers are not aligned it will be difficult to assemble the T M and it will cause damage to the discs 270 29Nm 2 81 3 Specified torque of bolt No 7 Unequal bolt tightening will cause disengagement problems and judder shudder e 3 ver height is equal after tightening If it is not equal then restart from item 3 E ge IL TT ET 5 m gt ri 7 T M Replace the T M For the pull type replace the release bearing with the genuine new one and apply specified genuine grease to the sliding surfaces appropriately For the push type replace the release bearing and the clutch sleeve with the genuine ones specified in the separate sheet Follow the maintenance manual issued by the vehicle manufacturer 000
18. ng mm can be easily set to the proper position It is acceptable that nuts or washers piled up to fit to the space are used as substitutes BDnnnunnnunpnunnaunn Installation of flywheel F W uunenrEwnpggabpaBudggagadagpnpnapnbpaugugewppudggaangagpaud Du Nissan Toyota Subaru Mitsubishi and Honda vehicles At the time of installation of the flywheel No 6 be sure to use the crank bolt flywheel mounting bolt specified on the list 132408 000000000000 00 300 9 Be sure to apply Adhesive 1324 to the thread ridges of the crank bolt for the Toyota vehicle before tightening it Otherwise engine oil will ooze from the bolt hole pguna nupnununupnuagadgpuanunupnugangpnaunugnuggdgpgdgpiun Tighten the crank bolt diagonally not at a time but for several times with equal force Finally tighten up it with the specified torque Then install the flywheel No 6 to the crank shaft in accordance with the maintenance manual n issued by the vehicle manufacturer Crank bolt tightening torque list
19. of kit Loosen the bolt No 7 and disassemble the kit es 75 Nm 6 6 7 6 00000000 DO NOT loosen the bolt 8 that was tightened with the specified torque before delivery If it is loosened by mistake apply a screw lock agent strong to it and tighten it with the specified torque 65 Nm to 75 Nm 6 6 to 7 6 2 00000000000000 Installation of pilot bearing 7 As for the vehicle model that the pilot bearing is required for the flywheel prepare the new and genuine parts and install them Refer to the list in page 7 M300 8 e RIT Installation of release bearing to pull type Honda vehicle 0000 nstall the release bearing to the clutch cover Assy No 1 Be sure to work on a stable bench Release bearing installation procedure To install the bea
20. ring easily follow the instructions below 1 GA 22271 422tRU0B8 THEORUT 2 Q A LEAOBP UHHACHREAUT 3 tTUBRADPS AX H amp 0709 2 IORN 8 BSL25444 hC229 hi MESSI RAN I AN 25970 BEEUVLU A A 70572 FERIFUIT 27 PIII OESOSRCUN ARB 12545 037 Remove the clutch disc 4A and place the 2 Tighten the bolts A 7 in the structural 3 When the bolt A 7 in the spacers at the three positions equally in drawing diagonally not at a time but structural drawing is loosened reference to the drawing below positions of for several times with equal force until while the bearing is supported the plate spring on the center plate the flywheel comes in contact with the with your hand the lever is Temporarily insert the release bearing from clutch cover lowered and the bearing is fixed the inside of the clutch cover As the bolt is tightened up the lever is raised up The lever tip should be fit to the proper groove of the bearing Bearing temporarily inserted Spacer VA tEREDES ECEU A UBE20mmnBE amp 6 5 7 Omm VA CORREA 09 O50t RUCTSU J72 EEROWECEACEY h FIERT YYv FEERTI EMELTRAULTOT factiiEE GU f Y Use a spacer with a diameter of approximately As the lever is raised the inner diameter of 20 mm and thickness between 6 5 mm and 7 0 the lever tip is increased and the beari
21. ructed to in this manual If a failure such as abnormal noise vibration odor or disengagement problem occurs during driving stop the vehicle immediately and have a licensed garage inspect the vehicle 0000000000 Applicable vehicle and model Hunu Applicable vehicle model Hunu 0000 Manufacturer Part No Clutch size Vehicle model Engine model NM012SD S13 14 MNM019SR SR20DET NM022SD S15 NM023SR NM032SD BNR32 0 0 0 0 BNR32 0 NM033SR BCNR33 1 D FQ D UD NMOSSHRW BNR32 early model and SECUN NMO3SHRWH BNR32 later model BCNR33 NMO33HRWT conversion model RB26DETT NM042SD BNR32 BCNR33 NMO43SR BNR32 later model BCONR33 NM052SD R34 NM053SR PNPS NM062SD 232 VG30DETT NM063SR 4200 TR TMO12SR SW20 3S GTE TMO32SD JZX90 100 110 1JZ GTE TOYOTA 0425 2JZ GTE TM043SR JZA80 JZ G ZM012SD FC3S 13B ZM013SR MAZDA ZM0228D 13B REW ZM023SR 3 0225 4 MITSUBISHI MMO023SR ai FM012SD GC8 EJ20 SUBARU FM022SD GDB 2B HONDA HM012SD 1 2 C30 3 M300 000000000 Components and structural drawing
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