取扱説明書 Installation manual
Contents
1. 7077 Do not change any release control function of the vehicle 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 f 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 16 7 sx NE2. Do not machine any part of this product otherwise the strength of each part 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 The bolts are the very important parts Use either genuine parts or t
3. 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 Assembly of parts C B AW Assy Assembly order Disc C Center hub Center plate gt Disc B gt Center plate Disc A Pressure plate gt Pivot ring Clutch cover Assy At the time of assembly be sure to match the painted marks on the outer diameter for positioning of the 1 2 3 5 and 6 M309 12 T CAUTION
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 Installation procedure 1 Disassembly of kit Loosen the bolt No 7 and disassemble the kit E Io A M309 CAUTION 36 7 38 Nm 3 7 3 9 kgm1 DO NOT loosen the bolt No 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 36 Nm to 38 Nm 3 7 to 3 9 kgm 9 2 Installation of pilot bearing
5. 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 Advice 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 200 3 0 mm 4 0mm 6200 Series 3 0 mm At new 4 0 mm 8 Be WARNING
6. Installation work has to be done by a professional installer who will use the product safely 3 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 For safety Please note the following as these are important warnings and cautions for our customers rca p cL E u XSWEXSERERISERES lgnoring this warning may cause death or extreme injury mm
7. Do not hit the spline teeth with the edge of the main drive shaft It will cause 2Sengagement problems or damage to the clutch disc n 111 8 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 Advice e If 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 e If the pedal position should be moved away from the floor adjust
8. e CAUTION a Ignoring this caution may cause injury or damage M309 2 Caution during handling 1 Ne 2 A 3 NB 4 A As this product is heavy handle carefully when removing it from the box C BRG As for the pull type NEVER hold the inner diameter of the diaphragm Otherwise the collar 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 a EF WARNIN
9. 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 9 ma WARNING Do not over use the clutch beyond the following limits M309 17 Operation limit list ltem Limit 10 11 12 M309 NN 12000 r mim Max engine rpm S 700 Nm 71 kgm S type 515Lbs ft Twin H 843Nm 86 kgm H type 621Lbs ft Max engine torque S447 1050 Nm 107 kgm S type 774Lbs ft Triple Ea 1260 Nm 128 kgm H type 929Lbs ft 2 0 mm xz Max disc wear Total 2 0 mm m 800 C Max friction surface temperature 9 0 mm Max release stroke azo A WARNING ae A WARNING WARNING
10. Bearing Press in Since all the vehicles are individual check the clutches and release bearings with installed to them actually Nissan genuine Darts number clutch sleeve 30501 A3800 12 mm 30501 S0160 22 mm 30501 N1601 14 mm 30501 K0404 24 mm 30501 U0200 16 mm 30501 K0510 26 mm 30501 80200 18 mm 30501 N1600 28 mm 30501 B6000 20 mm 30501 N8400 30 mm S For the pull type vehicles replace the bearing with the genuine new pull type bearing No modification is required M309 15 Caution during operation UN Z3 CAUTION CAUTION 500km 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 m
11. Flywheel mounting bolt Genuine parts HYUNDAI a Meee Release bearing i Genuine parts Parts to be prepared other than the above ones 1 We recommend you replace the release bearing for all vehicle models with a new one 2 15 240SX Release bearings shown in page 15 are required for the push type Nissan vehicles Especially for 240SX the clutch sleeve number is different to genuine one 3 We recommend you replace the flywheel mounting bolts for all vehicle models with new ones For the vehicle model not shown in the table above use bolts enclosed with the product 4
12. 879 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 8 9 3 Installation of release bearing to pull type Honda vehicle Assy Install the release bearing to the clutch cover Assy No 1 Be sure to work on a stable bench 7 Release bearing installation procedure To install the bearing easily follow the instructions below 1 4A 2 L CAN 3 1 Remove the clutch disc 4A and place the spacers at the three positions on the flywheel 2 equally positions of the leaf spring on the center plate Temporarily insert t
13. ERU Keep this manual EN i HULT RE BLUTER Installation manual EXEDY RACING CLUTCH 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 2013 3 7 lssued on Mar 7 2013 GR 77 lssued by EXEDY Corporation Aftermarket sales Department M309 Sie Installation manual introduction This installation manual includes useful information to prevent problems from occurring during installation 1 Please read through this manual before installation 2
14. Parts required additionally Manufacturer Vehicle model Engine model Parts No Parts required to be prepared NM012SD 30502 14601 319 914 ARRODET NM013HB Release bearing i Nissan genuine parts 30502 14601 Release bearing i Nissan genuine parts R20DET NM022SD ae ai SD 32202 B9500 Pilot bush Nissan genuine Darts NM032SD NM033SR dod x IJ i fi s enra meesoerr usos ELT Us Bazaar NM033HRWH 3 NM033HRWT NM042SD BE BONIS Beeps NM043SR Release bearing Genuine parts i y NM052SD NISSAN PNRI ugs NM053SR Release bearing Genuine parts NM062SD ede ODE NM063SR Release bearing Genuine parts 30502 14601 Release bearing i Nissan genuine parts Z V DE NM072HD z 9 RES i 12315 30P01 8pcs Flywheel mounting bolt i Nissan genuine parts NM082SDL 30502 14601 NE NM083SBL Release
15. A T M SIDE B F W SIDE EXEDY 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 i It should be assembled in such the direction that the identification mark above can be seen from the cover side i C B A Be careful of the direction location of the center hub The brim of center hub is located on between Disc C and B And teeth of center hub need catch teeth of Disc A also CAUTION If the marking is not met it will cause unbalance noise and vibration problems 7 WIE TRAE
16. Applicable vehicle and model Applicable vehicle model Manufacturer Part No Clutch size Vehicle model Engine model NM012SD NM013HB AO SR20DET NM022SD S15 NM032SD BNR32 BNR32 NM033SR BCNR33 NM033HRW BNR32 early model and NM033HRWH BNR32 later model BCNR33 NM033HRWT conversion model RB26DETT NM042SD BNR32 BCNR33 NM043SR BNR32 later model BCNR33 NISSAN NM052SD BNR34 NM053SR NM062SD Z32 VG30DETT NM063SR Z33 NM072HD VQ35DE Z33 early model a NM082SDL PATROL TB48DE NM083SBL 2 P NM092SD 200 KA24E 240SX S13 S14 NM093HB doeet KA24DE TM012SR SW20 3S GTE TM032SD JZX90 100 110 1JZ GTE rd TM042SD TOYOTA ZA 2JZ GTE TM043SR ri ids TM052SD ZN6 FA20 ZM012SD f 13B ZM013SR eom i MAZDA ZM022SD ZM023SR FD3S 13B REW MM022SD MM022HD N CP CT9A 4 MM023SR CN CP CT9 G63 MM023HR MITSUBISHI MM062SD MM062HD CZ4A 4B11 MM063SB MM063HB M309 4 Applicable vehicle model Manufacturer Part No Clutch size Vehicle model Engine model FM012SD FM013HB SES FM022S
17. Apply grease specified by the vehicle manufacturer to the spline hub then insert the shaft and wipe away any grease which is forced out CAUTION NO Assy 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 T M CAUTION If the centers are not aligned it will be difficult to assemble the T M and it will cause damage to the discs 27 29Nm 2 8 3 0kgm Specified torque of bolt No 7 X Unequal bolt tightening will cause disengagement pro
18. As the lever is raised the inner diameter of the lever tip is increased and the bearing can be easily set to the proper position 10 7 A 7 3 When the bolts A 7 in the structural drawing is loosened while the bearing is supported with your hand the lever is lowered and the bearing is fixed 4 1 FLW Installation of flywheel F W FW FW Nissan Toyota Subaru Mitsubishi Honda and Hundai 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 1JZ 2JZ 1324 Be sure to apply Adhesive 1324 to the thread ridges of the crank bolt for the Toyota 1JZ and 2JZ vehicle before tightening it
19. bearing Nissan genuine parts 30502 14601 NM092SD Release bearing Nissan genuine parts 240SX S13 14 KA24E DE NM093HB 15 N y Clutch sleeve i See page 15 SW20 3S GTE TMo12sR None i JZX90 100 110 90910 02103 JZA70 SE JO Flywheel mounting bolt TOYOTA genuine parts TOYOTA TM042SD PED El TM043SR Release bearing Genuine parts fab IE S ayo ZN6 FA20 TNO MZA e T Ye LER SEU Release bearing Genuine parts Mazda genuine counterweight NO 0 200000 N327 11 521A ZM012SD 200001 N351 11 521 Fess 198 ZM013SR Chassis No from 0 to 200000 200001 and later MAZDA Release bearing Genuine parts N351 11 521 ZM022SD Counterweight MAZDA genuine parts 9 TEREN ZM023SR Release bearing Genuine parts MM022SD MM022HD Flywheel mounting bolt Genuine parts EE lace MM023SR MM023HR Release bearing
20. the push rod in the opposite to the above M309 14 Release bearing and clutch sleeve for Nissan push type e 8 9 Additionally purchase the release bearing specified by us on page 8 9 e 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 aoe Clutch model Applicable vehicle Recommended sleeve model length NMO1x 14 SR20DET 24 26 mm NMO2x 15 SR20DET NMO3x R32 RB26DETT 14716 mm d Ex NMO06x Z32 VG30DETT 22 24 mm NMO07x Z33 VQ35DE Genuine Darts NM09x 240SX KA24E DE 18 20mm i I i i T l
21. D FM022HD GDB EJ20 EJ25 SUBARU FM023HB GDA 2 FM032SD 200 BP BL5 TM052SD ZC6 FA20 HM012SD NA1 2 C30 32B HONDA HM052SR AP1 2 F20 22C HYUNDAI RM012SD 2 0 L Turbo G4KF M309 5 Components and structural drawing NO Number of pieces No Description Pull type Push type Assy CCA Clutch cover Assy CCA i PP 1 Pressure plate PP O IMP 1 2 Center plate IMP Twin 1 Triple 2 A CDA Clutch disc A CDA C CDC 1 Clutch disc C CDC Triple 1 B CDB eee disc B CDB 1 1 FWR 9 Flywheel ring FWR i FW 1 Flywheel F W AIL EA Bolt A 8 Washer Pivot ring 12 D 8 9 Crank bolt See page 8 9 FG 1 Center hub Triple 1 M309 6 PULL TYPE i IWIN PLATE PUSH TYPE TRIPLE PLATE M309 s
22. G aa 2 BA WARNING A WARNING 3 eee 4 AE EF WARNING BX 5 WARNING M309 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 by EXEDY Do not modify this product unless instructed to in this manual If a failure such as abnormal noise vibration odor or disengagement problem occurs during driving stop the using immediately and have a licensed garage inspect the vehicle
23. Genuine parts MITSUBISHI MM062SD CZ4A XEM MM062HD Flywheel mounting bolt Genuine parts MM063SB MMO063HB Release bearing i Genuine parts M309 8 Manufacturer Vehicle model Engine model Parts No Parts required to be prepared Manufacturer FM012SD GC8 mae FM013HB Release bearing i Genuine parts FM022SD s IJ XA IJ gt ifi Et myo 3 GDB EJ20 25 FOM NSR TAR MERR Release bearing i Genuine parts SUBARU FM023HB fab TE S ayo GDA BP BL EJ20 25 FMOdeSD ee ANE don MEREN Release bearing Genuine parts AB TE aro ZC6 FA20 NMOS28DE rure AE ER al ah Release bearing Genuine parts 90011 PR7 000 Flywheel mounting bolt HONDA genuine parts NA1 2 C30 32B HM012SD Release bearing Genuine parts HONDA Flywheel mounting bolt Genuine parts AP1 2 F20 22C HM052SR Release bearing Genuine parts
24. Otherwise engine oil will ooze from the bolt hole Tighten the crank bolt diagonally not at a time but for several times with equal force Finally tighten up it with the specified torque NO0 Then install the Flywheel No 6 to the crank shaft in accordance with the maintenance manual issued by the vehicle manufacturer Crank bolt tightening torque list Manufacturer Engine model Tightening torque SR20DET 83 93 Nm 8 5 9 5 kgm iis BBS DER 142 152 Nm 14 5 15 5 kgm on VG30DETT 83 93 Nm 8 5 9 5 kgm VQ35DE 83 93 Nm 8 5 9 5 kgm KA24D DE 140 150 Nm 14 3 15 3 kgm TB45DE 150Nm 15 3 kgm 1JZ GTE 2JZ GTE 49 Nm 5 0 kgm 1 Note 1 TOYOTA FA20 85 Nm 8 7 kgm EJ20 25 69 78 Nm 7 8 kgm SUBARU FA20 85 Nm 8 7 kgm 4G63 127 137 Nm 13 14 kgm MITSUBISHI 4B11 130Nm 13 3 kgm C30 32B 103 Nm 10 5 kgm HONDA F20 22C 127 Nm 13 0 k
25. ating 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 3 In the early stage it is not abnormal if subtle noise or chattering occurs This is due to the characteristics of metal facings 4 Due to the clutch design the multiple disc clutch may cause a rattle noise when disengaged This is not an abnormal condition 5 6 M309 ak A WARNING ak He A WARNING
26. blems and judder shudder M309 13 6 3 Confirm that lever height is equal after tightening If it is not equal then restart from item 3 7 TM FR 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 TM CAUTION
27. gm SR G4KF 118 127Nm 12 13 kgm 1JZ 2JZ 12 Note 1 As for the Toyota 1JZ and 2JZ tightening below must be carried out after the crank bolts are M309 tightened with the tightening torque shown in the table above See the drawing in page 12 11 1 5 Paint the bolt head with a color paint for marking 90 Tighten the crank bolt a further 90 degree relative the paint mark Check the paint mark located on the right side 6 FW 8 LET Mazda vehicle Fix the Mazda genuine counterweight see page 8 to the flywheel No 6 with the supplied special bolts x 54 74 Nm 5 5 7 5 kgm
28. he bolts included as auxiliary parts in the box Do not reuse the old bolts after un tightening 18 For further information EXEDY Corporation Aftermarket sales Department 572 0822 1 1 1 1 1 1 Kidamotomiya Neyagawa shi Osaka 572 0822 Japan TEL 072 822 7138 FAX 072 821 6541 E mail soc exedy co jp EXEDY Globalparts Corporation 8601 Haggerty Road South Belleville MI 48111 TEL 800 346 6091 FAX 734 397 7300 E mail amsales dcc us com EXEDY Australia PTY LTD 21 Fiveways Boulevard keysborough Victoria 3173 AUSTRALIA TEL 61 3 9701 5556 FAX 61 3 9701 5684 EXEDY Clutch Europe Ltd Unit 2 Rokeby Court Manor Park Runcorm Cheshire WA7 1RW UK TEL 44 1928 571850 FAX 44 1928 571852 EXEDY Middle East Fzco P O BOX 18199 Warehouse No ZE5 amp ZE6 Jebel Ali Free Zone Jebel Ali Dubai U A E TEL 971 4 883 2244 FAX 971 4 883 2500 EXEDY New Zealand Ltd 151 Wairau Road Glenfield Auckland NEW ZEALAND TEL 64 9 444 0901 FAX 64 9 444 0903 EXEDY Guangzhou Co Ltd No 406 E Area Longfu Car Accessories Center Hengfu Road Guangzhou CHINA TEL 86 20 83489166 FAX 86 20 83489370 M309 19
29. he release bearing from the inside of the clutch cover RAKE Bearing temporarily inserted 2 0 mm 6 5 7 0mm Use a spacer with a diameter of approximately 20 mm and thickness between 6 5 mm and 7 0 mm It is acceptable that nuts or washers piled up to fit to the Space are used as substitutes M309 7 A Tighten the bolts A 7 in the structural drawing diagonally not at a time but for several times with equal force until the flywheel comes in contact with 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
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