- Place the driven disk into the flywheel with the long side of the disk hub facing outward and insert the centering rod into the disk and into the hole in the flywheel, as shown in Figure 108. This rod should enter the splined part of the driven disk and have a neck that fits the crankshaft guide. An old gearbox shaft can also be used for this purpose. An experienced mechanic can center the driven disk by eye.
Figure 108. After inserting the driven disk, insert the centering rod (1) into the disk and flywheel bearing.
Figure 109. Tighten the new clutch bolts evenly and crosswise to a tightening torque of 15 Nm.
- Place the clutch basket on the centering rod and attach it to the driven disk. When reinstalling the old clutch, the marks made with a punch must match. The new clutch can be installed in any way.
- Tighten the new clutch bolts evenly and crosswise to a torque of 15 Nm. While doing this, hold the flywheel from turning. In this case, you should insert and remove the centering rod from time to time to ensure centering.
- Secure the gearbox to the engine and install the power unit on the vehicle (section 2.1.2) or install the gearbox according to the instructions section 8.1. Lightly lubricate the splined joints of the clutch shaft and the outer surfaces of the clutch release bearing guide sleeve with graphite grease (molykote BR2 lubricant is recommended).
- After installing the gearbox, adjust the clutch cable. There are two nuts screwed onto the end of the cable. The purpose of the adjustment is to bring the height of the clutch pedal to the height of the brake pedal. To adjust, first loosen the outer nut and then move the second nut located underneath it. When this nut is screwed on, the pedal rises, and when it is unscrewed, the clutch pedal falls. After adjustment, tighten the outer nut while holding the inner nut.
After adjustment, check the clutch pedal travel. It should be 180 mm. This is measured by measuring the difference between the pedal's released position and the pedal's fully depressed position. When measuring, first measure the distance from the floor to the released pedal, and then measure the distance from the floor to the fully depressed pedal. The difference between the two measurements is the clutch pedal stroke.