Clutch: Service and Repair

Removal
- Remove engine with transmission.





- Remove wires on starter and wires for backup light switch.
- Remove accelerator linkage circlip at top and disconnect accelerator linkage.
- Unscrew four mounting nuts and take transmission off of engine.





- Hold flywheel with toothed segment P 201 a and spacer sleeve. Make sure that spacer sleeve fits engine with adequate clearance.
- Loosen bolts holding clutch pressure plate to flywheel evenly and diagonally one or two threads, until the spring pressure stops (prevents distortion on clutch pressure plate).
- Check clutch components for wear and damage.

Installation

- After cleaning, check clutch contact surface of flywheel for wear. If necessary. machine surface and smooth with emery cloth. Replace the flywheel. if necessary.
- Lubricate sliding surfaces of clutch release with multi-purpose grease containing MoS2 and splines of input shaft with Optimoly HT.
- Lubricate needle bearing in flywheel with about 1 cm3 (1, 5 grams) of MoS2 grease.
- Install clutch with special tool 9102 to center in flywheel.
- Center clutch pressure plate on flywheel.
- Tighten bolts evenly and diagonally to prevent distortion on cover. Tighten bolts to specified torque. Use Special Tool P 201 a and a spacing sleeve to hold the flywheel.
^ Tightening torque: 25 Nm (18 ft lb).

NOTE: Keep grease containing MoS2 off of sleeves of lever shaft (release shaft).





- Bolt transmission on engine. Attach release pivot when bolting on release bearing. Check for correct position through opening in transmission case.
^ Tighten mounting nuts to: 45 Nm (32 ft lb).
- Install engine with transmission.
- Coat release and positioning levers with specified grease and install.
- Make basic clutch adjustment.