You will need: the tools needed to remove the gearbox and clutch, and a socket «at 17», large screwdriver.
1. Remove the gearbox (see «Removal and installation of a transmission») and grip (see «Removal and installation of clutch»).
2. Mark in any way the relative position of the flywheel and crankshaft.
Note. The flywheel must be mounted on the crankshaft in only one possible position. To facilitate the installation of the flywheel, we recommend that you mark the relative position of the parts.
3. Turn out six bolts of fastening of a flywheel. At the same time, use a screwdriver to keep the flywheel from turning by first screwing in one of the gearbox mounting bolts.
4. Having unscrewed bolts and holding a flywheel, remove a lock plate of bolts.
5. Remove the flywheel from the crankshaft flange.
6. Check the condition of the flywheel rim teeth and replace the flywheel if damaged.
7. Replace or repair the flywheel if there are marks and scuff marks on the surfaces of the clutch driven disc.
8. If cracks or deep nicks appear on the flywheel flange, replace the flywheel.
You can check and repair the flywheel in a workshop with special equipment.
Pic. 5.7. Flywheel: 1 - surface adjacent to the crankshaft flange; 2 - a place to check the surface for attaching the clutch; 3 - a place to check the runout of the bearing surface of the clutch driven disk
Surface non-flatness 3 (pic. 5.7) fit of the clutch driven disk should not exceed 0.06 mm.
The non-parallelism of the contact surfaces of the clutch driven disk and surface 2 for fastening the clutch must not exceed 0.1 mm.
The runout of the flywheel on surfaces 3 and 1 must not exceed 0.1 mm.
To remove deep scratches and scuffs, surface 3 of the flywheel can be machined, the thickness of the layer of metal to be removed should not exceed 1 mm. Simultaneously with surface 3, it is necessary to machine surface 2, maintaining the size between them (0,5±0,1) mm. When turning, keep surfaces 3 and 1 parallel.
Note. Before installing the flywheel, apply an anaerobic thread locker to the threads of the flywheel mounting bolts, having previously degreased the bolts and the threaded holes for them.
Install the flywheel in the reverse order of removal, aligning the holes on the flywheel and crankshaft flange (they are arranged asymmetrically).