Thursday 15 January 2009

Clutch removal

Here's my cheap Indian clutch removal tool installed and in action, compressing the flange down onto the five springs.



This releases the compression on the circlip, allowing it to be removed from its position and freeing up the clutch plates. When the circlip is removed you can unscrew and remove the clutch removal tool and simply lift off the clutch plates, steel plates, flange and springs.

To continue you need to remove the 22mm nut that holds down the clutch spider and crownwheel. It is secured with a tab washer which first needs to be released. To remove the nut you need to prevent the assembly from rotating with your spanner/socket, and the best way to do this is using a clutch holder tool:



When done you can simply lift off the spider. Note that the shaft has a bearing bush on it which is easy to miss - it's just a well-fitted metal sleeve that aids rotation between the spider and crownwheel. You can now tease off the chain and lift off the large crownwheel. Finally, you should find one or more shims beneath the crownwheel on top of the end plate bearing.

This picture shows the gearbox end plate with the layshaft poking through the end plate bearing. On the bearing you can see what are two shims:

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