SAFARI

CLUTCH

6. INSPECTION OF COMPONENTS

Check clutch disc hub splines for damage and

wear. The clutch disc should slide easily on gear

box drive shaft but should not have excessive

play and wobble.

ii. Check torsion damper mechanism springs for

distortion, damage etc. For this purpose, hold

drive shaft in vice. Insert clutch disc and slide it

as far back as possible. Rotate disc by hand.

Rattling noise and excessive play indicates

damaged torsional dampingmechanismand such

disc must be replaced.

iii. Check disc facing for wear, cracks, contact

pattern, burning marks and oil contamination.

Facings with any of the above defects or worn

out beyond permissible limits must be replaced.

Note

It is recommended to replace a NEW genuine

clutch disc for any above mentioned

defects.We

do not recommend removal and replacing of clutch

facings.

We do not recommend overhauling of the clutch

pressure plate assembly. However, before

refitment, the assembly should be checked for

serviceability and should conform to the data of

clutch pressure plate assembly given on page 3.

Caution

Prior to installing a new clutch disc, check for

face run-out and straighten, if required.

Ensure that the clutch facing material is not

contaminated with oil or grease as this shall result

in clutch slipping.

7. INSTALLATION OF CLUTCH ONVEHICLE

Proceed in reverse order of removal of clutch.

However, following care must be taken during

installation :

Clean friction face of flywheel and check for

cracks, scoring, burn marks or unevenness. If

necessary, machine flywheel friction face just

to clear the defect.

Check spigot bearing in crankshaft for free

rotation. Replace sticky/damaged bearing. Fit new

bearing after filling with bearing grease and press

in the retaining cover. Lightly apply grease (3%

MoS2) on the disc splines. Install disc and

pressure plate assembly (The shorter length of

the splined hub on the clutch disc must face

towards the flywheel). Press aligning arbor

through the pressure plate assembly and clutch

disc and centralize clutch disc on flywheel by

locating the front end of the arbor in flywheel

spigot bearing.

Locate pressure plate housing on flywheel dowels

in original position with aid of marks and align its

mounting holes with tapped holes in the flywheel.

Screw in clutch mounting screws with spring

washers. Aligning arbor still in position, tighten

mounting screws evenly and equally (alternately

and cross wise) in small steps. Tighten these

screws in the same sequence to 3 mkg torque.

Note

Do not mix clutch mounting bolts with other

fasteners. Do not use longer or shorter screws.

Longer screws may not tighten the clutch at all.

Shorter screws will not provide enough threads

to achieve desired tightening.

While tightening the clutch mounting screws

check aligning arbor for continuous free sliding

to ensure concentric installation of clutch disc

which will avoid trouble when installing the gear

box.

Fill pocket of release sleeve with (3% MoS2)

grease.

Lubricate the fork, spring plate and ball pin bearing

area with (3% MoS2) grease.

Lubricate slave cylinder fork bearing surface with

(3%MoS2) grease.