I have a 1990 Honda Civic Hatchback with a Zc swap, the stock 4spd transmission with a Clutch Masters clutch and pressure plate.

Here's my situation: I begin by starting the car by pushing in the clutch/turning the key. Immediately when the car starts with the clutch pushed in it squeals and you can smell clutch. When I let of the clutch it seems fine. However, when I push it in again the engine rpms drop at idle and the car seems like its gonna stall. It will barely get into and sometimes not at all. I tried adjusting the clutch cable but it seems its not able to be adjusted further. Someone care to venture a guess?

 

sounds like a faulty throwout bearing. what components were replaced and were they new?

 

The clutch fork also has excessive play. The components are about 4 years old (Throwout bearing, pilot bearing, clutch, pressure plate, stock flywheel, OEM 4 spd) low miles though

 

yeah its your throw out bearing. I have a close friend that i do all his mechanic work for and he had this same problem only on a 94 civic. If what your describing is accurate...IM 95% sure its the throwout bearing expecially if the clutch fork has excessive play...just drop the tranny and inspect it all...

 

the ball bearings fell out of the throwout bearing when i removed it...lol

 

I guess I'm gonna have to drop the transmission and figure it out. Crap.

 

Your cable may have stretched or maybe the wrong length? Has the adjustment always been near the max?
You say low miles, does that mean it hasn't been driven? Maybe something is rusted?

 

I've been thinking that it might be that as well. Its never really been towards the max, I've never had to adjust it either except for the first time I drove the car after installing the new motor 5 year ago. It's just been driven back and forth to work about 2 miles every day and it's not driven in the winter. Nothing seems to be rusted either gonna just have to check it out I suppose. I'm gonna get it up on jack stands here pretty soon, but I haven't decided if I just want to pull the motor and trans together to just pick up a stock D16A6 with an Si trans