EFORTISSIMO Racing Stage 2 HD Sport Clutch Kit User Manual

1. Product Overview

The EFORTISSIMO Racing Stage 2 HD Sport Clutch Kit is designed for enhanced performance in compatible vehicles. This kit provides a balance between street usability and track performance, offering smooth engagement while handling significantly increased power over standard clutches. It is engineered as a direct factory replacement, requiring no modifications for installation.

The kit incorporates high-grade components, including carbonized friction material for superior burst strength and heat tolerance, and a heavy-duty sprung center with heat-treated springs for increased reliability. The pressure plate features a special single diaphragm design to boost clamp load, ensuring a precise and modulated feel.

2. Kit Components

The complete EFORTISSIMO Racing Stage 2 HD Sport Clutch Kit includes the following components:

• EFORTISSIMO Racing Heavy-Duty Pressure Plate: Engineered for increased clamp load and smooth engagement.
• EFORTISSIMO Racing Stage 2 HD Carbon Sprung Disc: (219mm, 24 spline) Features carbonized friction material for high performance and durability.
• Release Bearing: Essential component for disengaging the clutch.
• Pilot Bearing: Supports the input shaft of the transmission.
• Alignment Tool: Facilitates proper alignment of the clutch disc during installation.
• Installation Guide: General instructions for clutch installation.

Image: All components of the EFORTISSIMO Racing Stage 2 HD Sport Clutch Kit, including the blue pressure plate, carbon sprung disc, release bearing, pilot bearing, alignment tool, and a general installation guide card.

3. Vehicle Compatibility

This clutch kit is compatible with the following vehicle applications:

• 1994 - 2001 Acura Integra (B18 1.8L DOHC 4CYL)
• 1994 - 1997 Honda Civic Del Sol VTEC (B16 1.6L DOHC 4CYL)
• 1999 - 2000 Honda Civic Si (B16 1.6L DOHC 4CYL)
• 1997 - 2001 Honda CR-V (B20 2.0L DOHC 4CYL)

Note: Always verify compatibility with your specific vehicle model and engine code before installation.

4. Specifications

5. Setup and Installation

Installation of a clutch kit requires specialized tools and automotive knowledge. It is highly recommended that installation be performed by a certified professional mechanic to ensure proper function and safety.

General Installation Guidelines:

1. Safety First: Ensure the vehicle is securely lifted and supported. Disconnect the battery.
2. Transmission Removal: Carefully remove the transmission from the vehicle, following the vehicle manufacturer's service manual.
3. Old Clutch Removal: Remove the old pressure plate and clutch disc. Inspect the flywheel for hot spots, cracks, or excessive wear. Resurface or replace the flywheel if necessary.
4. Pilot Bearing Replacement: Replace the old pilot bearing with the new one provided in the kit.
5. Release Bearing Replacement: Replace the old release bearing (also known as throw-out bearing) with the new one. Inspect the clutch fork and pivot ball for wear.
6. Clutch Disc and Pressure Plate Installation: Using the provided alignment tool, install the new clutch disc and pressure plate onto the flywheel. Ensure the clutch disc is oriented correctly (usually marked "Flywheel Side" or "Transmission Side"). Tighten pressure plate bolts evenly and to manufacturer specifications.
7. Transmission Reinstallation: Carefully re-install the transmission, ensuring the input shaft splines align correctly with the clutch disc. Do not force the transmission into place.
8. Fluid Check: Refill transmission fluid to the correct level.
9. Initial Break-in: Follow the break-in procedure outlined in the included general installation guide. This typically involves a period of gentle driving to allow the clutch surfaces to properly seat.

Important: Failure to observe proper installation procedures may void the product warranty and lead to premature clutch failure. Refer to the vehicle's specific service manual for detailed steps.

6. Operating Principles

The clutch system in your vehicle is responsible for transmitting power from the engine to the transmission, allowing for smooth gear changes and vehicle starts. When the clutch pedal is pressed, the release bearing disengages the pressure plate from the clutch disc, interrupting power flow. When the pedal is released, the pressure plate clamps the clutch disc against the flywheel, re-establishing power transmission.

The EFORTISSIMO Racing Stage 2 HD Sport Clutch Kit is designed to provide a firm yet manageable engagement, suitable for both daily driving and spirited performance. Its enhanced clamp load and durable friction material contribute to efficient power transfer and extended lifespan under demanding conditions.

7. Maintenance

Proper maintenance can extend the life of your clutch kit. While the clutch itself is a wear item, certain practices can optimize its performance and longevity:

• Avoid Riding the Clutch: Do not keep your foot on the clutch pedal unnecessarily, as this causes premature wear to the release bearing and clutch disc.
• Smooth Engagement: Practice smooth and gradual clutch engagement to minimize shock to the drivetrain and reduce wear.
• Proper Shifting: Ensure complete clutch disengagement before shifting gears to prevent grinding and wear on the transmission synchronizers.
• Fluid Checks: For hydraulic clutch systems, regularly check and maintain the clutch fluid level and condition as per your vehicle's service manual.
• Regular Inspections: During routine vehicle maintenance, have a qualified mechanic inspect clutch components for signs of wear or damage.

8. Troubleshooting

If you experience issues with your clutch system, consider the following common problems and potential solutions:

• Slipping Clutch:
  • Symptom: Engine RPM increases but vehicle speed does not, especially under acceleration. Burning smell.
  • Possible Causes: Worn clutch disc, oil/grease on clutch surface, weak pressure plate, improper clutch adjustment (for cable systems), or air in hydraulic system.
  • Solution: Inspect clutch components for wear. Check for leaks. Bleed hydraulic system. Professional inspection and replacement may be required.
• Clutch Chatter/Shudder:
  • Symptom: Vibration or shaking during clutch engagement.
  • Possible Causes: Warped flywheel, worn clutch disc, worn pressure plate, worn engine/transmission mounts, or oil/grease on clutch surface.
  • Solution: Inspect flywheel and clutch components. Check mounts. Clean clutch surfaces if contaminated.
• Difficulty Shifting/Grinding Gears:
  • Symptom: Gears are hard to engage, or grind when shifting, even with the clutch pedal fully depressed.
  • Possible Causes: Clutch not fully disengaging (dragging), air in hydraulic system, worn pilot bearing, or worn transmission synchronizers.
  • Solution: Bleed hydraulic system. Inspect pilot bearing. Check clutch pedal free play/adjustment.
• Stiff Clutch Pedal:
  • Symptom: Excessive force required to depress the clutch pedal.
  • Possible Causes: Worn release bearing, worn clutch cable (if applicable), faulty pressure plate, or issues with hydraulic components (master/slave cylinder).
  • Solution: Inspect release bearing and cable. Check hydraulic system for proper function.

For persistent issues, it is advisable to consult with a qualified automotive technician.

9. Warranty Information

The EFORTISSIMO Racing Stage 2 HD Sport Clutch Kit is backed by a comprehensive warranty to ensure your peace of mind.

• Warranty Period: 12 months or 12,000 miles, whichever comes first.
• Coverage: This warranty covers manufacturing defects and material flaws.
• Exclusions: The warranty does not cover damage due to improper installation, misuse, abuse, racing, or normal wear and tear.

For full warranty terms and conditions, please refer to the documentation provided with your purchase or contact EFORTISSIMO Racing customer support.

10. Technical Support

EFORTISSIMO Racing is committed to providing excellent customer service and technical assistance.

• Online Support: EFORTISSIMO offers industry-leading technical support online.
• Contact: For technical inquiries or assistance, please visit the official EFORTISSIMO Racing website or refer to the contact information provided with your product.