Recommendation: When replacing the clutch disc, it is advisable to replace the pressure plate as well (basket), even if there are no visible 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 during rotation or makes a clearly audible noise (see "Clutch - checking the technical condition").
To do the job, you will need a mandrel to center the clutch disc.
Removing
1. Remove the gearbox (see "Gearbox - removal and installation").
Tip: If replacing the pressure plate assembly (baskets) not planned, we mark its position on the flywheel with a center punch.
2. Socket or box wrench by 8 mm unscrew the six bolts securing the basket to the flywheel, keeping the flywheel from turning with a mounting spatula or a large slotted screwdriver.
3. Remove the basket and driven disk.
4. Prying off the ends of the spring with a slotted screwdriver, remove them from the protrusions of the release bearing clutch.
5. Remove the release bearing assembly with the clutch from the guide sleeve.
6. Remove the spring.
7. To replace the fork and its sleeve, prying with a screwdriver, remove the rubber protective cover of the clutch release fork.
8. We take out the plastic bushing of the fork from the crankcase hole.
9. Having shifted upwards, we remove the lower end of the fork lever axis from the seat and remove the clutch release fork.
We wash the removed parts in kerosene. We replace damaged and worn parts.
Installation
1. We clean the spline part of the input shaft of the gearbox and the guide sleeve of the release bearing from dirt and old grease.
2. We apply a thin layer of SHRUS-4 grease on them and on the working surface of the clutch fork axis.
3. Install drive parts in the clutch housing (fork, spring, release bearing) in the reverse order of removal. Apply grease to the working surface of the fork.
4. We insert the centering mandrel into the hole in the end of the crankshaft.
5. We install the clutch driven disk on the mandrel, orienting it so that the side where the disk hub protrudes more is facing the gearbox.
6. Install the basket.
7. Aligning the previously made marks with a socket wrench by 8 mm evenly tighten the bolts of the basket. Finally tighten the bolts to a torque of 19.1-30.9 N·m (2.0-3.2 kgf·m).
8. Remove the centering mandrel.
9. Install the gearbox in the reverse order of removal.
10. We check the operation of the clutch release drive and adjust the length of the cable (see "Clutch release actuator - adjustment").