Removing and Installing Flywheel

Removing and installing flywheel

Tools





Preliminary work
Preliminary work
1. Remove transmission.
2. Remove clutch pressure plate and clutch.

Removing flywheel
Removing flywheel

Clutch And Flywheel:

Toothed Segment:

1. Block the flywheel. To do this, attach a suitable toothed segment toothed segment 201a or toothed segment 9538/1 to a screw hole in the crankcase so that at least one tooth is in contact with the starter teeth. Place a washer (approximately 5 mm) under the segment if necessary.

Fastening Screws:

WARNING: Danger of injury if flywheel falls down!
^ Danger of injury to feet.
--> Wear protective gear (e.g. safety shoes, gloves).
--> Work carefully (get another person to help you to install and remove the flywheel, if necessary).

Note:
^ To make it easier to re-install a used flywheel, use a felt-tip pen to mark the crankshaft stub and flywheel before removing it. This makes it easier to install it again later.
^ If the flywheel is stuck, loosen it by levering it at the sides with two screwdrivers and then remove it.

2. Remove the flywheel. To do this, loosen the ten fastening screws crosswise.

Note:
^ Clean the crankshaft stub before installing the flywheel (remove rust).
^ Use a special metal-polishing pad (e.g. Never Dull) for this.

3. Remove the flywheel and clean the flange.

Installing flywheel
Installing flywheel

Note:
^ Clean the crankshaft stub before installing the flywheel (remove rust).
^ Use a special metal-polishing pad (e.g. Never Dull) for this.

1. Clean the flange and fit the flywheel (align according to the previously applied markings if necessary). Screw on the ten fastening screws hand-tight.

Toothed Segment:

2. Block the flywheel. To do this, attach a toothed segment 201a or toothed segment 9538/1 to a screw hole in the crankcase so that at least one tooth is in contact with the starter teeth. Place a washer (approximately 5 mm) under the segment if necessary.

Fastening Screws:

3. Tighten the ten new fastening screws crosswise. Tightening torque 44 ft. lbs.. Torque angle 90° Torque angle 30°.
4. Remove toothed segment.

Subsequent work
Subsequent work
1. Install transmission.
2. Install clutch pressure plate and clutch.