5 - speed manual transmission
1. Clutch release lever
2. Sleeve
3. Clutch release fork
4. Sleeve
5. Clutch basket
6. Clutch disc
7. Release bearing
Withdrawal
1. Remove the transmission assembly.
2. Remove release bearing.
3. Remove the clutch basket and clutch disc from the engine.
Note:
Insert special tool (09411-11000) into the splined hole to prevent disc displacement.
Do not clean the clutch disc or release bearing with cleaning solvents.
4. Remove the bushing and clutch release fork assembly.
Installation
1. Before installing the clutch basket and clutch disc assembly, apply grease 10 mm from the end of the transmission input shaft.
Note: Recommended lubricant: CASMOLY L9508.
2. Fix the clutch disc to the flywheel using a special tool (09411-11000).
3. Install the clutch basket assembly to the flywheel and temporarily tighten the bolts three turns at a time in order «criss-cross».
Note: Tightening torque: 25-36 Nm.
4. Align the bearing (A) with clutch release fork (IN), and then install it into the body sleeve.
Attention. Apply multipurpose grease (CASMOLY L9508) on the bearing bush, the contact point of the clutch release fork (IN) and the inner surface of the sleeve (WITH).
Note:
- Bearing sleeve groove: 0.5 - 1.0 g.
- Contact surface of the clutch release fork: 0.3 - 0.5 g.
- Sleeve neck: 0.8 - 1.2 g.
5. Install the lever on the clutch release fork.
6. Install the gearbox on the engine.
Attention. If the gearbox is installed on the engine without following this paragraph, the release bearing may separate due to the rotation of the clutch release fork.
Checking the technical condition
Clutch basket assy
1. Check the petals of the Belleville spring for wear and uneven height.
2. Check pressure plate surface for wear, cracks and discoloration.
3. Check the rivets for secure fit and replace the clutch basket assembly if necessary.
Clutch disc
1. Check the surface of the clutch disc for loose rivets, uneven contact, deterioration due to sticking, sticking oil or grease; replace the clutch disc if it is out of specification.
2. Measure the free thickness of the clutch disc.
Note: Limit value: 0.3 mm.
3. Check the free play of the damper springs; if they fail, replace the clutch disc.
4. Clean the input shaft splines and install the clutch disc.
If the disc does not spline smoothly or there is excessive play, replace the clutch disc and/or transmission input shaft.
Clutch release bearing
Attention. Clutch release bearing filled with grease. Do not use solvents or oil to clean it.
1. Check the bearing for wear, damage or abnormal noise. Check the contact points of the bearing with the diaphragm spring for wear.
2. Replace the bearing with a new one if the contact surface of the release fork has abnormal wear.
Clutch release fork
If there is abnormal wear on the contact surface of the release fork with the bearing, replace the release fork with a new one.
6 - speed manual transmission
1. Clutch disc
2. Clutch basket
3. Gearbox
4. Flywheel
Withdrawal
1. Remove the transmission assembly.
2. Remove the bolts from the clutch basket. To avoid bending the bolts, loosen them in order «criss-cross».
Installation
Attention. When installing a previously used clutch basket, install it with the clutch disc assembly.
1. Replace the basket and clutch disc as a set.
Note:
If only the disc is replaced, the loss of initial downforce due to abnormal operation of the adjusting ring may cause a clutch slip problem.
In addition, if only the clutch disc is replaced, there may be problems with power transmission interruption, since the thickness of the disc cannot be guaranteed to meet regulatory requirements.
2. Apply the required amount of grease to the splines of the clutch disc and transmission input shaft.
Note:
Possible malfunctions associated with the wrong amount of lubricant:
Lack of lubrication: Increased spline wear and poor clutch function.
Too much lubrication: centrifugal force splattering of lubricant and consequent slipping of the clutch due to lubrication of the clutch disc and loss of friction forces.
3. The clutch disc must be installed with the marked side «T/M SIDE» (gear side) outside (to yourself).
Note:
Possible malfunctions associated with installing the disk with the other side out:
Grinding of the concentric slave cylinder on the transmission side against the surface of the flywheel.
Improper clutch disengagement may result in improper gear shifting or unusual noise.
Breakage of the concentric working cylinder. In this case, the concentric slave cylinder must be replaced with a new one.
4. In the process of installing the clutch disc and basket, you should use a special tool (A).
5. Tighten the clutch basket bolts. To avoid bending the bolts, tighten them in order «criss-cross».
Note: Tightening torque: 24.5 - 35.3 Nm.
Attention.
- Do not tighten the bolts immediately to the required torque in one go. This can cause the basket to bend and vibrate, as well as improper release of the pressure plate.
- Tighten the mounting bolts to the required torque. Failure to do so may result in incorrect torque transmission or loosening of mounting bolts.
6. Install the transmission assembly.
7. Remove air from the concentric working cylinder.