Clutch

Removal

PROCEDURE

1. Remove the transmission (refer to subsection 9.1).

2. Mark the position of the clutch on the flywheel.

3. Gradually loosen the bolts in a criss-cross pattern.

4. Remove the clutch, noting the position of the friction disc.

Inspection. WARNING: It is recommended to replace the complete clutch assembly with release bearing, even if only individual parts require replacement.

PROCEDURE

1. Carefully clean the clutch by wiping it with an alcohol-based solvent.

2. Check the friction linings for wear.

3. If the distance from the friction lining surface to the rivet heads is less than or equal to 0.3 mm, replace the friction linings.

4. Replace the linings if oil contamination, signs of deformation, cracks or slipping marks are found.

5. Check the splines of the friction disc hub, the springs and the integrity of the rivets.

6. If oil is found on the friction disc, find and eliminate the cause before installing a new disc.

7. Check the pressure plate condition and the tightness of the riveted joints by rocking the plate.

8. If signs of overheating (bluish discoloration) are visible or the diaphragm spring has weakened, replace the clutch.

9. Check the ground surfaces of the pressure plate and the flywheel.

10. Remove minor defects by grinding. Replace parts with severe damage.

11. Check the release bearing and replace it at the slightest defect.

Installation

PROCEDURE

1. Thoroughly clean the flywheel and clutch surfaces.

2. Install the friction disc so that the hub faces away from the flywheel.

3. Holding the friction disc in place, install the clutch cover assembly onto the locating dowels, aligning the marks made during removal.

4. Tighten the bolts by hand.

5. Center the friction disc.

6. The disc can be centered by turning a bar in the hub while resting it in the flywheel bore, or by using a special alignment arbor.

7. Tighten the clutch housing bolts evenly, in several steps, to the specified torque.

8. Apply a thin coat of high-melting-point grease to the transmission input shaft splines and the release fork shaft.

9. Install the transmission.