Recommendation. When replacing the driven clutch disc, it is advisable to also replace the pressure plate (basket), even if there are no noticeable signs of wear on its working surface. The fact is that during operation its working surface wears out and the rigidity of the diaphragm spring weakens. It is also necessary to replace the release bearing if it has play, sticks when rotating, or makes an audible noise (see above, "Checking the technical condition of the clutch").
To perform the work, you will need a mandrel for centering the driven clutch disc.
Note: Operation shown on an automated gearbox.
Removal
1. Remove the gearbox (see "Manual gearbox - removal and installation" or "Automated gearbox - removal and installation").
Recommendation. If replacing the pressure plate assembly (basket) is not planned, use a center punch to mark its position on the flywheel.
2. Using an 8 mm socket or open-end wrench, unscrew the six bolts securing the basket to the flywheel, holding the flywheel from turning with a mounting blade or a large slotted screwdriver.
3. Remove the basket and driven disk.
4. Pulling towards you, remove the release bearing 1 from the guide sleeve. Remove the lever 2 from the crankcase opening together with the protective cover 3. Wash the removed parts in kerosene. We replace damaged and worn parts.
Installation
1. Clean the splined portion of the gearbox input shaft and the release bearing guide sleeve from dirt and old grease.
2. Apply a thin layer of SHRUS-4 grease to them and to the working surface of the clutch release fork axle.
3. Install the drive parts into the clutch housing (fork, spring, release bearing) in the reverse order of removal, apply plastic grease to the working surface of the fork.
4. Insert the centering mandrel into the hole in the end of the crankshaft.
5. Install the driven clutch disc on the mandrel, orienting it so that the side where the disc hub protrudes more faces the gearbox.
6. Install the basket.
7. Having aligned the previously made marks, use an 8 mm socket wrench to evenly tighten the basket mounting bolts. Finally tighten the bolts to a torque of 19.1–30.9 Nm (2.0-3.2 kgcm).
8. Remove the centering mandrel
9. Install the gearbox in the reverse order of removal.
10. Check the operation of the clutch release drive and, if necessary, eliminate the detected malfunction.