Remove/Install
Removing- Remove engine with transmission.
- Remove cable from starter and cable from switch for back-up light.
- Detach retainer from top ball socket and remove throttle pull rod.
- Unscrew hex bolt from release shaft and pull out shaft.
- Disconnect transmission by removing the 4 securing nuts. Use Special Tool P 119 for the upper securing nut at starter.
- Remove clutch retaining bolts by slackening bolts uniformly. Remove clutch from flywheel. If the flywheel must be removed, use Special Tool P 238 a to counter.
Inspection of Components
Inspect the following individual parts for wear and damage and replace if necessary. Have parts on hand ready for installation. Lubricate bearings and sliding surfaces.
Flywheel:
Scoring and scorching. Remachining no longer possible, as clutch release bearing may contact damper of driven plate, depending on tolerances.
Needle Bearing in flywheel:
If necessary, repack with MoS2 multipurpose grease (new filling 1 cc)
Clutch Controls:
Check release fork for ease of travel and signs of wear. Lubricate bearings and sliding surfaces with the specified lubricants
Release Bearing:
Release bearings are filled with a special grease and consequently must not be washed out. Check for wear.
Guide Tube:
Check for signs of wear, release bearing must move smoothly on guide tube. Coat sliding surface with multipurpose grease with MoS2.
Seal Rings:
Check on crankshaft and transmission shaft
Clutch Plate:
- Inspect splines. The clutch plate must move easily on the transmission shaft without any radial play.
- Check rivets, spring plates and torsion elements for secureness, cracks or signs of damage. In case of doubt, replace clutch plate.
- Inspect clutch lining. If the lining is oily, burnt, cracked or unevenly worn, install a new clutch plate.
- Check thickness of clutch plate lining.
^ Size new: (compressed) 9.3 ± 0.3 mm
^ Size worn: (compressed) 7.5 mm with symmetrical wear.
- Clutch linings cannot be replaced.
- Check clutch plate for lateral run-out at lining. Permissible lateral run-out max. 0.6 mm, measured approx. 2-3 mm from circumference.
Clutch Pressure Plate:
- The design makes no provision for overhauling or repair of the clutch pressure plate. Inspection is restricted to "dry cleaning" and removal of dust with compressed air and emery cloth and a close visual inspection.
- Clean clutch, but never wash pressure plate. If necessary, clean contact surface of pressure plate with emery cloth, remove scorch marks by polishing. Blow entire mechanism clean with compressed air.
- Check ends of diaphragm springs for marks indicating contact with the clutch release bearing. Marks of a depth of up to 0.3 mm are insignificant.
- Inspect contact surface of pressure plate for cracks, scorching and wear. Check deformation with a steel ruler. Pressure plates with an inward deformation of up to 0.3 mm (use feeler gage to measure) are still usable.
- Check spring connection between pressure plate and cover for cracks. Check that rivets are secure. Replace pressure plates with damaged or loose rivets.
Installation
- Mount clutch on flywheel. The friction surfaces must be clean and free of grease. Use mandrel P 370 (or shortened transmission shaft) to center clutch plate. Tighten bolts uniformly in diagonally opposite sequence. Tightening torque 25 Nm (18 ft lb).
- Lubricate sliding surfaces of clutch release mechanism with MoS2 multipurpose grease and splines of transmission shaft with Optimoly HT.
- Insert release fork in release bearing and use a suitable piece of adhesive tape to hold fork provisionally in installation position.
- Bolt transmission to engine.
- Insert release shaft in release fork from outside.
- Remove adhesive tape through assembly aperture.
- Tighten securing bolt for release shaft (M6 x 16).