取扱説明書 Installation manual
Contents
1. Replace the T M Purchase a new release bearing and apply grease to sliding surface Follow the maintenance manual issued by the vehicle manufacturer Do not hit the spline teeth with the edge of the main drive shaft It will cause i Bngagement problems or damage to the clutchdise 9 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 CAUTION Advice2. Do not machine any part of this product otherwise the strength of each part will be reduced and may fail prematurely 10 WARNING 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 11 WARNING The bolts are the very important parts Use either denuine parts or the bolts included as auxiliary Darts in the box Do not reuse the old bolts after un tightening H301 FM
3. 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 5 WARNING This clutch system is specially designed for racin9 DUrDoses therefore Dedal 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 6 I The life of a clutch may be adversely affected by driving technique and driving conditionS Especlally the friction material is worn prematurely in a r
4. Loosen the screw on the operatind cylinder side of the orifice mechanism At this time pay attention to the spring incorporated in it 3 2 2 Remove all the built in parts two springs and two plastic Darts 4 Pay attention not to omit the gasket and tighten the screw 5 Re install the orifice mechanism to the vehicle and bleed air H301 13 Clutch orifice Master cylinder Operating cylinder Caution during operation 500km 1 NNW _ H301 After installation drive carefully and gently Travel for approximately 500 km in a City area If the clutch is used in a
5. 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 Dart Caution during installation 2 3 4 5 H301 WARNING WARNING WARNING WARNING WARNING 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
6. RB20DET Flywheel mounting bolt Genuine parts 1 RB25DET NISSAN Release bearing Genuine Darts Flywheel mounting bolt Genuine Darts R34 RB25DET NH04SD1 Release bearin9 Genuine Darts 12315 30P01 Flywheel mounting bolt Nissan 9enuine Darts Z33 VQ35DE NHO05SD1 8 8 DCS Release bearing Genuine Darts 7 mn AE92 89 5 ie AE101 111 4A GE TH01SD AW11 85 6 8 6 Release bearing Genuine Darts 4 El SW20 ST205 3S GTE THO2SD Release bearing Genuine parts SXE10 38 GE Pilot bearing _Genuine parts 90910 02103 JZX90 100 110 Flywheel mounting bolt ITOYOTA genuine Darts TOYOTA JZA70 RE Dj Release bearing i Genuine parts Flywheel mounting bolt Genuine parts NCP13 1NZ FE TH06SD
7. CAUTION EXEDY Be careful of the direction location of the clutch disc which compriseSs EXEDY lt should be assembled in such the direction that the identification mark above can be seen from the cover side If the marking is not met 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 CAUTION 6 Assy H301 11
8. Release bearing Genuine parts H301 Flywheel mounting bolt Genuine parts EF8 9 B16A HH06SD Release bearing Genuine parts FW As for the vehicle model that the parts number of the flywheel mounting bolt is not specified prepare new bolts used for the genuine flywheel 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 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 clut
9. 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 expansion or deformation which causes disengagement problems temporarily or permanently Stop driving and allow the clutch to cool down 8 WARNING Do not over use the clutch beyond the following limits H301 16 Operation limit list gt Limit Item 225 200 225 series 200 series SA 10000 mim Max engine rpm 460 Nm Max engine torque 47 kgm Max friction surface temperature 9 0 mm Max release stroke 9 WARNING
10. Release bearing Genuine Darts Flywheel mounting bolt Genuine Darts EP82T 91T 4E FTE TH07SD Release bearing Genuine Darts H301 Manufacturer Vehicle model Engine model Parts No Parts reduired to be prepared Mazda genuine counterweight NO 0 lt 200000 N327 11 521A 200001 N351 11 521 93 138 CI Chassis No from 0 to 200000 200001 and later MAZDA Release bearing Genuine Darts N351 11 521 Counterweight i MAZDA genuine parts FD3S 13B REW ZH01SD1 Release bearing Genuine parts Flywheel mounting bolt Genuine parts CN CP CT9A 4G63 MHO1SD1 Release bearing Genuine Darts MITSUBISHI Flywheel mounting bolt Genuine Darts 9 COO Release bearing Genuine parts
11. Pilot bearing Genuine parts GC8 EJ20 i Ms Release bearing Genuine Darts Flywheel mounting bolt Genuine parts SUBARU Pilot bearing Genuine Darts GDB EJ20 Fi62sDtl Release bearing Genuine parts Flywheel mounting bolt Genuine Darts Flywheel mounting bolt Genuine Darts HoNpA 1 Ra MS Release bearing Genuine parts EG6 EK4 9 B16A B HHO02SD Flywheel mounting bolt Genuine parts DC2 B18C Release bearing Genuine Darts Flywheel mounting bolt Genuine Darts EP3 DC5 FD2 K20A HH03SD Release bearing Genuine Darts R NN NA1 2 C30 32B HH04SD1 HONDA genuine parts Release bearind i Genuine Darts Flywheel mounting bolt i Genuine Darts 4 0 ZI
12. Set up the center bar 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 is recommended for this process T M CAUTION Failure in centering of the clutch disc No 2 will lead to difficulty in the assembly of the transmission and damage to the disc 27 29Nm 2 8 3 0kgm Specified torque of bolt No 4 Unequal bolt tightening will cause disengagement problems and judder Shudder 7 3 Confirm that lever height is equal after tightening If it is not equal then restart from item 3 8 T M
13. Do not modify this product unless instructed to in this manual lf a failure such as abnormal noise vibration odor or disengagement problem occurs durind drivind stop the vehicle immediately and have a licensed garage inspect the vehicle Applicable vehicle and model Applicable vehicle model Manufacturer Part No Clutch size Vehicle model Engine model NHO01SD1 225 S13 14 SR20DET NH02SD1 225 S15 4 NHO03SD1 225 R32 R33 RB20DET 25DET NH04SD1 225 R34 RB25DET NHO05SD1 225 Z33 VQ35DE AE92 89 5 THO1SD 200 AE101 111 4A GE AW11 85 6 TH02SD 225 SW20 ST205 3S GTE TOYOTA THO3SD 225 oo 3S GE TH04SD1 225 JZA70 1JZ GTE TH06SD 200 NCP13 1NZ FE TH07SD 200 EP82T 91T 4E FTE ZH01SD1 225 FD3S 13B REW MAZDA ZH02SD 225 FC3S 13BT ZH03SD 200 NA NB8 BP MHO01SD1 225 CN CP CT9A 4G63 MITSUBISHI MHO6SD 225 CZ4A 4B11 FH01SD1 225 GC8 EJ20 SUBARU FH02SD1 225 GDB HHO1SD 200 AP1 F20C HHO02SD 200 EG6 EK4 9 DC2 B16A B B18C HHO
14. Keep this manual SS 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 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 2003 06 03 lssued on June 3 2003 SBC lssued by EXEDY Corporation Sports BC H301 1 Installation manual introduction This installation manual includes useful informa
15. 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 H301 12 10 lf the pedal position should be moved away from the floor adjust the push rod in the opposite to the above GDB GDB P14 Subaru Impreza GDB The GDB Impreza is equipped with the orifice mechanism in order to prevent an abrupt clutch engadement Since this orifice mechanism may cause premature wear of carbon or a slip disable it by implementing the steps shown below See page 14 1 Remove the orifice on the side of the clutch operating cylinder 2
16. Please note the following as these are important warnings and cautions for our customerS lgnoring this warning may cause death or extreme injury CAUTION H301 2 Caution during handling 3 CAUTION CAUTION CAUTION 3 CAUTION 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 color or C ring may be deformed leading to release of the bearind
17. 2 0 6 5 7 0 2 0mm As the lever is raised the inner diameter of the lever tip is increased and the bearing can be easily set to the proper Dosition Use a spacer with a diameter of approximately 20 mm and thickness between 6 5 mm and 7 0 mm lt is acceptable that nuts or washers piled up to fit to the SDace are used as substitutes 4 F W Installation of flywheel F W 1 G 6 Nissan Toyota Subaru Mitsubishi and Honda vehicles 3 When the bolt 5 in the structural drawing is loosened while the bearind is Supported with your hand the lever is lowered and the bearing is fixed 5 FW At
18. condition where the friction surface is not contacting fully with the mating surface it will cause slip Durning juddershudder or short life 14 2 2 It isS recommended to re adjust the stroke after the break in period Due to the nature of clutch for racing Durposes 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 depending on the operating conditionS 4 WARNING a
19. the time of installation of the flywheel No 3 be sure to use the crank bolt flywheel mounting bolt specified in the list in page 6 1324 Be sure to apply Adhesive 1324 to the thread ridges of the crank bolt for the Toyota vehicle before tightenind it 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 H301 1 NO Then install the flywheel No 3 to the crank shaft in accordance with the maintenance manual issued by the vehicle manufacturer Crank bolt tightening torque list Manufacturer Engine
20. 3SD 200 EP3 DC5 FD2 K20A HONDA HH04SD1 225 NA1 2 C30 32B HH05SD 200 CL1 H22A HH06SD 200 EF8 9 B16A H301 4 Components and structural drawing NO No Description Number of pieces Assy CCA 1 Clutch cover Assy CCA CDA Clutch disc CDA F W Flywheel F W Bolt Washer 6 Crank bolt See Da0e 6 ES gt H301 5 Parts required additionally Manufacturer Vehicle model Engine model Parts No Parts reduired to be prepared Flywheel mounting bolt Genuine Darts S13 14 SR20DET NHO1SD1 Release bearing _Genuine parts 32202 B9500 Pilot bush Nissan genuine parts S15 SR20DET NH02SD1 Release bearing Genuine parts
21. For further information BC EXEDY Corporation Sports BC 572 0822 1 1 1 Kidamotomiya Neyagawa shi Osaka 572 0822 Japan TEL 072 822 7138 FAX 072 821 6541 E mail sbc 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 Al Dubai U A E TEL 971 4 883 2244 FAX 971 4 883 2500 H301 18
22. acing 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 H301 15 foreseeable Preventative maintenance before the discs are worn out is a key factor to maintain steady Derformance Maximum facing wear Facing thickness Manufacturer Part No Max facing wear at New NH01SD1 NH02SD1 NH03SD1 NH05SD1 RN 2 Nissan NH04SD1 4 2mm 5 5mm THO1SD TH06SD TH07SD 3 6mm 4 6mm Toyota THO02SD TH03SD 3 6mm 4 6mm TH04SD1 4 2mm 5 5mm ZH01SD1 4 2mm 5 5mm Md ZH02SD 3 6mm 4 6mm ZH03SD 3 6mm 4 6mm MH01SD1 MH06SD Mitsubishi NN FH01SD1 FH02SD1 2 5 5mm HH01SD 3 1mm 4 6mm HH02SD HH03SD i BOT HONDA HHO05SD HH06SD HH04SD1 4 2mm 5 5mm 7
23. ch Installation procedure 1 Disassembly of kit Loosen the bolt No 4 and disassemble the kit 2 Installation of pilot bearing 6 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 6 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 H301 8 A Release bearing installation procedure To install the bearing easily follow the instructions belo
24. e Fix the Mazda genuine counterweight see page 6 to the flywheel No 3 with the supplied special bolts 54 74 Nm 5 5 7 5 kgm 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 Assy NO lt Assembly order gt Clutch disc Clutch cover Assy At the time of assembly be sure to match the painted marks on the outer diameterfor positioning of the 1 and 3
25. model Tightening torque SR20DET 83 93 Nm 8 5 9 5 kgm 4A GE 74 Nm 75 RE 3S GTE 108 Nm 11 0 kgm 3S GE 83 Nm 8 5 kgm ROMA 1NZ FE 88 Nm 9 0 kgm 4E FE 88 Nm 9 0 kgm 49 Nm 5 0 kgm 1 Note 1 sugAmu EJ20 69 78 Nm 7 8 kgmi MITSUBISHI 4B11 130Nmi13 3 kgm B16A B B18C 103 Nm 10 5 kgm K20A 122 Nm 12 5 kgm HONDA F20C 127 Nm 13 0 kgm C30 32B 103 Nm 10 5 kgm 1JZ 10 Note 1 As for the Toyota 1JZ tightening below must be carried out after the crank bolts are tightened with the tightening torque shown in the table above See the drawing in page 10 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 H301 10 2 GO F W 6 Mazda vehicl
26. tion to prevent problems from occurrind during installation 1 Please read through this manual before installation 2 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
27. w 2 3 2XSX 8 3 Tighten the bolts 5 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 1 Remove the clutch disc which comprises 2 3 2 7 and 8 and place the spacers at the three positions on the flywheel equally positions of the knock pins Temporarily insert the release bearing from the inside of the clutch cover Bearing temporarily inserted 5 2
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