SAFARI

CLUTCH

4. SPECIFICATIONS

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 damping mechanism and

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.Please refer to specifications given.

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 ON VEHICLE

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 flywheel (pilot bearing)

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 and pilot

bearing I.D. Install disc and pressure plate

assembly (Before installation ensure that the disc

face stamped with 'flywheel side' mates the

flywheel face). 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

(pilot bearing).

Locate pressure plate assy. on flywheel dowels,

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 3.2 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.

Lightly smear the fork, spring plate and ball pin

bearing area and cover the tube surface with

(3% MoS2) grease.

Lightly smear the slave cylinder fork bearing

surface with (3% MoS2) grease.

8. CLUTCH ACTUATION MECHANISM REMOVAL

Connect bleeding tube, to bleeding screw on

slave cylinder.

Loosen bleeding screw on slave cylinder by 1/2

to 3/4 turn. Operate clutch pedal number of times

and pump out fluid into a clean container.

Remove bleeding tube

Disconnect pipe connections from master

cylinder.

Disconnect pipe connection from slave cylinder.

Remove split pin and clevis pin, locking master

cylinder push rod fork end with clutch pedal.

Unscrew and remove two master cylinder

mounting screws. Pull out master cylinder with

push rod.

Unscrew and remove slave cylinder mounting

screws and pull out slave cylinder.