Cluch Replacement

1. Remove The Gearbox. Service and Repair





2. Remove the clutch. Fit centering drift P/N 5111. This is intended as a safety precaution. Back off the pressure plate mounting bolts cross-wise, a couple of turns at a time, to avoid warping the plate. Remove the pressure plate and the driven plate.





3. To change and replace the pilot bearing. Check that the bearing runs freely, without binding. Replace the bearing if the play is excessive. Withdraw the bearing by means use tool P/N 4090. Use drift P/N 1426 to fit the bearing. Tap in the bearing until it bottoms on the crankshaft.

4. Carefully check the pressure plate for overheating damage, cracks, scoring or other damage on the friction surface. The pressure plate cannot be dismantled and must be replaced as a complete unit.

5. Check the pressure plate for flatness, to ensure that it is not warped by more than 0.2 mm (0.08 in).





Place a steel straight-edge diagonally across the friction surface. Measure the gap between the straight-edge and the inside diameter of the pressure plate (see figure). This must not exceed 0.2 mm.

Clearance between the straight-edge and the friction surface at the outside diameter of the pressure plate is never permissible. Carry out this check by means of the straight-edge at several points.
6. Carefully check the diaphragm spring. If the spring is damaged or cracked at any point, replace the pressure plate.
7. Disconnect the release lever from the clutch housing and remove the bearing.
8. Check the release bearing for binding. Spin the bearing a few times while applying light pressure, so that the balls are in contact with the races. The bearing should rotate without binding at any point.
9. Use grease P/N 1161138-1 and grease the following parts:





1 - Splines and shaft end (thin film)





2 - Release bearing





3 - Pivot ball and seat of the clutch fork. (Applies to early models without plastic pivot ball)





4 - Cable mounting and pedal bearing

NOTE: Grease must never come into contact with the friction lining in the driven plate. Neither may grease come into contact with the pressure plate or flywheel.





10. Fit the bearing and the release lever. Press the release lever spring onto the pivot ball in the housing. Check that the spring on the lever is in the correct position, i.e. not in the groove in the pivot ball stud. (As from the 1985 models, there is no groove in the pivot ball stud.)





11. Fit the driven plate and the pressure plate. Make sure that the flywheel and pressure plate are completely free from grease before assembling the parts. Wash with degreasing agent and steel wool. Wipe with a piece of clean cloth. Fit the driven plate and pressure plate. When fitting the driven plate, make sure that the hub faces outwards, away from the flywheel.

Fit centering drift P/N 5111 for guiding the clutch into place. Fit the bolts and tighten them cross-wise a couple of turns at a time, to avoid warping.
12. Fit the gearbox. Service and Repair