Clutch D/G, With Freewheel
Clutch D/G, with Freewheel
1 - Freewheel inner race
• Checking rotating and locking direction of freewheel => [ Checking rotating and locking direction of
freewheel ]
• Checking brass sleeves for wear => [ Checking upper and lower brass sleeves in freewheel
inner race for wear ]
• Checking splines
3 - Rectangular rings
• Checking for wear => [ Checking rectangular rings for wear ]
4 - Freewheel with freewheel housing
• Checking rotating and locking direction of freewheel => [ Checking rotating and locking direction of
freewheel ]
7 - Coated plates
• Checking for wear => [ Checking coated and outer plates for wear ]
8 - Outer plates
• Checking for wear => [ Checking coated and outer plates for wear ]
11 - Plate spring
• Replace in case of signs of wear or if dished washer tips are bent
• Check for cracks
13 - Piston "D"
• Check for cracks
• Perform sound test by striking with a screwdriver: Clear sound - pistons OK, thudding sound - cracks in pistons
15 - Cylinder "D/G"
• Check for scoring from lining discs on inner and outer circumference => [ Check cylinder for scoring
from lining discs ]
• Checking splines
• Checking for cracks in area of groove for circlip
19 - Plate spring
• Replace in case of signs of wear or if dished washer tips are bent
23 - Coated plates
• Checking for wear => [ Checking coated and outer plates for wear ]
24 - Outer plates
• Checking for wear => [ Checking coated and outer plates for wear ]
Checking rotating and locking direction of freewheel
• Freewheel inner race - 2 - must be able to turn in a clockwise direction and must lock in a counter-clockwise direction when turned.
If there is no locking effect:
- Replace freewheel with freewheel housing - 1 -.
Checking upper and lower brass sleeves in freewheel inner race for wear
- Check contact surfaces of brass sleeves - arrows - at inside of freewheel inner race for wear.
• Contact surfaces must not be heavily scored and/or show blue discoloration.
In case of deep grooves and/or blue color:
- Replace freewheel inner race.
If no blue discoloration and only small grooves are detected, proceed as follows:
- Sandpaper (600 grit, oiled) contact surface 1 to 2 times.
- Carefully wipe off with a clean rag and check contact surfaces.
• Contact surfaces must now be like new.
If scores cannot be removed in this manner:
- Replace freewheel inner race.
Checking rectangular rings for wear
• Always replace rectangular rings. However, conclusions can be drawn from the signs of wear of the rectangular rings regarding the quality of contact surface for rectangular rings. Evaluating the rectangular rings for wear is therefore essential.
If rectangular rings show strong axial wear of more than 0.3 mm - arrow 1 - (slight wear of outer edges is normal):
- Replace freewheel inner race.
If rectangular rings show strong radial wear of more than 0.3 mm - arrow 2 - (for comparison, measure thickness of new rectangular ring):
- Replace cylinder "F".
Checking coated and outer plates for wear
Signs of overheating on outer plates point to worn coated plates. Evaluate signs of wear as follows:
A Spots of discoloration of outer plate caused by overheating in distance of more than 20 mm: Outer and coated plates OK, can be reused.
B Spots of discoloration of outer plate caused by overheating in distance of less than 20 mm: Outer and coated plates worn, must be replaced.
C Tarnish blue/brown at outer and/or inner area of outer plate: Outer and coated plates overheated and worn, must be replaced.
Check cylinder "D/G" for scoring from lining discs
- Check cylinder "D/G" at inner and outer circumference for signs of wear caused by lining discs.
• Coated plates must not get caught in scoring.
If scoring - arrows - caused by coated plates are greater than 0.5 mm:
- Replace cylinder "D/G".