Often, especially in the morning, my clutch engagement feels "stepped" somewhat. It would feel like it engages at one point after letting up on the clutch, then catch at the "real" point of engagement about 3cm later. This only happens when letting up on the clutch for normal driving. During spirited driving, it's either impossible to feel or non-existent.

I was wondering what the cause of this might be. The most likely cause I can think of is that the machine shop I took my flywheel to surfaced it improperly.

 

You are not going to like this answer but your release bearing actuating rod needs to be removed, cleaned, greased and reinstalled. I have had this happen twice (two different transmissions). The transmission must be pulled to get it out. Remove the release bearing then remove the bolt holding the release bearing fork to the shaft. Pull the shaft out from the side of the transmission.

Now whenever I have a transmission out I lube the shaft. It's real easy right up to the time you comnnect the transmission to the engine. SORRY!!!!

 

No need to say sorry...hehe. Funny you suggested that because I actually did take time to clean and regrease that part despite the fact that nobody suggested that to me when I had the tranny out. Perhaps the grease wore out somehow?

Was the "stepped" feeling that bothersome for you to pull the tranny? Mine is noticeable, but is not too much of a problem when driving. Next time I drop the tranny, I'll make sure to grease the hell out of that release fork.


[Modified by ALF, 10:15 PM 2/12/2003]

 

Yea, mine got to the point that the clutch would slip in that "in between area" from the first release to the second. Bye Bye clutch! That's when I discovered the sticking rod. What kind of grease did you use? It needs to be high temp so that it does not flow when hot and contaminate the clutch. Also when it gets hot it flows out of the shaft sleeve.

 

I used some Valvoline high-temp multi-purpose grease good for up to 400 degrees F. I was in a bind looking for the recommended Honda grease, and used the Valvoline for the release bearing along with the release rod and everything covered with old grease. I either didn't put enough grease or the Honda grease is a "must."

Thanks for the tip. I've been trying to diagnose this problem for a very long time.

 

I have sucessfully used brake caliper grease. You can get it at any good auto parts store. It is specifically designed to be used in hot areas.

 

I used the valvoline high temp synthetic grease as well. It seems to be ok. The only time it feels "stepped" is on cold mornings when I first depress the clutch. After that is seems to be fine.