To Fit

Before re-assembling the clutch, check the condition of the clutch shaft seal located in the primary drive chaincase, and the condition of the support bearing in the flywheel.
1. Fit the pressure plate, clutch plate and slave cylinder with release bearing as one unit into the flywheel housing.

NOTE: Lubricate the clutch shaft splines sparingly with molybdenum disulphide paste.

Push the clutch shaft into engagement with the clutch plate splines and into the support bearing in the flywheel.
Fit two of the pressure plate bolts, but do not tighten them.





The hardened side of the release bearing must face towards the clutch.





2. Finally, tap in the clutch shaft so that it is locked by the snap ring in the primary drive sprocket.





3. Bolt the slave cylinder to the primary chaincase. Apply thread sealing compound to the bolts.
4. Fit the plastic propeller to the end of the clutch shaft.
5. Fit the seal, cover and wire clip in front of the clutch shaft.
6. Bolt the pressure plate unit to the flywheel.
7. Get an assistant to press down the clutch pedal and remove spacer ring 83 90 023 or 87 91 618.

CAUTION: Don't depress the clutch pedal further than necessary to remove the spacer. The lip seal may otherwise be pressed out too far, and hydraulic fluid will then leak out and the seal will be damaged.





8a Pull the movable locking ring towards the slave cylinder housing while the assistant keeps the clutch pedal depressed.





8b On the later version of the slave cylinder:
When the clutch has been fitted, push the plastic sleeve against the release bearing.
9. Fit the flywheel housing cover.
10. Fit the preheater hose.
11. Fit the bonnet.