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  • Clutch installation Procedure

1. Closely examine the old clutch unit during removal of the clutches. If there are any grooves, thermal cracks and hot spot, the flywheel must be resufaced, or replaced during each clutch installation. 

2. Check the transmission and engine oil seal for possble leaks. Replace necessary. 

3. Before installing the pressureplate and flywheel, they should be wiped clean of any oils. Be sure to use clean hands, and a clean rag with an alcohol-bsed solvent while cleaning. 

4. Install a new bushing or pilot bearing. If lubribation is necessay use SAE 30 Weight or Thinner petroleum oil. 

5. Inspect the bearing retainer and clutch form for possible wear such as flat spots, or burrs. If wear is found replace the bearing retainer/ clutch fork. Using white, heat resistant grease lightly lubricate the bearing retainer, transmission input shaft, and contac point of bearing and clutch fork. 

6. Check athat all dowel pins are in good condition and in place 

7. Face clutch disk with "flywheel side" lael against flywheel. If no Label is present, make sure that the clutch dampener spring are facing the transmission. 

8. After mating the cover assembly with the flywheel, insert the proper alignment tool and hand thighten the bolts. When tightening the bolts to manufacturers specifications use a star pattern. 

9. Check the clutch oerational system for wear, leak, and function. Replacing the clutch cable is strongly recommended as well as chencking the hydraulic fluid and bleeding the system.

 

  • Clutch Troubleshooting Guide

Condition Cause Correction
No Release 1. Improper linkage operation 
2. improper pedal travel 
3. Loose linkage
4. Faulty friction disc 
5. Defective hydralic 
6. Fork and bearing not assembled properly
7. Friction disc hub binding on imput splines 
8. Friction disc warped or bent. 
9. Faulty pilot bearing 
10. Friction disc installed backwards 
(Flywheel shid facing pressure plate)
11. Misalignment betweeen engine and transmission
1. Correct as required 
2. Adjust linkage 
3. Replace disc 
4. Install properly and lubricate levers at releas bearing with wheel bearing grease 
5. Repair or replace master, slave, or lines 
6. Install Disc properly 
7. Check motor mounts and bellhouse
Clutch Slipping 1. Oil or grease contamination on friction surfaces. 
2. Leaking transmission input shaft seal. 
3. Leaking engine main seal. 
4. Excessive lubrication of the transmission input shaft. 
5. Improper ferr play adjustment. 
6. Defective release mechanism 
7. Incorrect cover or disc 
8. Disc installed backwards. 
9. Flywheel not resurfaced or improperly resurfaced. 
10. Installation error 
11. Driver abuse (riding the pedal) 
12. Normal wear
1. Adjust Linkage 
2. Correct as required 
3. Install new disc and correct leak at its source 
4. Replace disc 
5. Replece pressure plate flywheel
Grabbing 1. Oil or grease contamition on friction surfaces. 
2. Leaking transmission input shaft seal 
3. Leaking engine main seal. 
4. Execessive lubriction of the transmission input shaft. 
5. Bent cover. 
6. Worn clutch cable. 
7. Worn splines on input shaft. 
8. Loose engine mounting
1. Install new disc and corret leak to engine or transmission 
2. Replace input shaft 
3. Tighten or replace mountings 
4 .Replace pressure plate or flywheel 
5. Sand off if superficial; replace burned or heat-checked parts.
Noise 1. Worn pilot bearing 
2. Worn release bearing 
3. Defective transmission input shaft bearing 
4. Installation Error 
5. Incorrect disc or clutch 
6. Disc installed backward 
7. Improper free play adjustment 
8. Fork improperly installed. 
9. Misalignment
1. Replace bearing 
2. Install properly and lubricate fork levers at bearing 
3. Repair or replace 
4. Replace the bearing 
5. Check motor mounts and bell housing