- remove the gearbox;
- mark the position of the clutch assembly in relation to the flywheel with a marker or paint;
- using a special tool or a screwdriver, lock the flywheel ring gear teeth to prevent it from turning;
Figure 5.9. Location of the clutch mounting bolt (1)
- gradually loosen bolts diagonally 1 (figure 5.9) clutch assembly mountings by turning each bolt half a turn until the spring force is released and the bolts can be loosened by hand;
- remove the pressure plate, while supporting the driven plate so that it does not fall out;
- clean the clutch release bearing from dirt, but do not use solvents;
- wipe the flywheel with gasoline.
To check the serviceability of the clutch disc:
- check the condition of the clutch pressure plate. Traces of wear on the ends of the pressure spring should be no more than 0.3 mm;
- check the reliability of the spring connection between the pressure plate and the clutch housing. Scratches and missing or damaged rivets are not allowed;
- check the pressure plate for cracks, burns, and surface wear;
- using a steel ruler and a feeler gauge blade, check the flatness of the pressure plate working surface. The flatness of the pressure plate should not exceed 0.2 mm;
- check the condition of the flywheel friction surface for cracks, burns and surface wear;
- check the condition of the friction linings of the driven clutch disc and if there are traces of oil or mechanical damage, replace the driven disc;
- measure the thickness of the clutch driven disc linings. If their thickness is less than the permissible value or if the rivet heads are close to the working surface, replace them or the clutch driven disc;
- check the condition of the release bearing, which should rotate easily, evenly and quietly and there should be no play in it. The working surface of the bearing acting on the compression spring must be smooth, without cracks, local corrosion or wear;
- a faulty clutch release bearing can be identified without removing it from the vehicle by pressing the clutch pedal while the engine is running. If noise occurs when you press the clutch pedal, the clutch release bearing is faulty and needs to be replaced;
- if there is oil in the clutch housing, the rear crankshaft sealing ring must be replaced.
To install the clutch disc:
- lubricate the splines in the driven disk hub with a thin layer of special grease based on molybdenum disulfide;
Note: When installing a new driven disc or pressure plate, remove the anti-corrosion protection from them.
- install the driven disc onto the flywheel so that the spring of the disc shock-absorbing hub is directed outward, towards the gearbox;
- when reinstalling a previously removed clutch pressure plate, check that the marks made before removal are aligned;
Caution! The lubricant layer must be thin and even, otherwise, when the clutch is operating, excess lubricant will be thrown onto the clutch working surfaces, which may impair its operation. When installing the driven disk, make sure that no oil gets on its friction linings, even in small quantities. Therefore, before installation, wipe the mating surface of the flywheel and the surface of the pressure plate with a clean rag, install the driven disk with clean hands.
- tighten the clutch mounting bolts so that the driven clutch disc is pressed, but at the same time can still move to the sides;
- using a special tool 0213/0214 or the old primary shaft of the gearbox, center the clutch disc relative to the flywheel;
- after centering the driven disk, gradually tighten the clutch housing mounting bolts diagonally to a torque of 20 N·m;
- remove the mandrel from the driven disk;
- lubricate the splined portion of the gearbox input shaft, the clutch release bearing guide sleeve and the fork tips with a thin layer of MOLYKOTE BR2 PLUS special grease;
- install the clutch release bearing;
- install the gearbox.