SAFARI

5 CLUTCH 4. SPECIFICATIONS 6. INSPECTION OF COMPONENTS i. 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 : l 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. l 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). l 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. l 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. l Fill pocket of release sleeve with (3% MoS2) grease. l Lightly smear the fork, spring plate and ball pin bearing area and cover the tube surface with (3% MoS2) grease. l Lightly smear the slave cylinder fork bearing surface with (3% MoS2) grease. 8. CLUTCH ACTUATION MECHANISM REMOVAL l Connect bleeding tube, to bleeding screw on slave cylinder. l 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. l Remove bleeding tube l Disconnect pipe connections from master cylinder. l Disconnect pipe connection from slave cylinder. l Remove split pin and clevis pin, locking master cylinder push rod fork end with clutch pedal. l Unscrew and remove two master cylinder mounting screws. Pull out master cylinder with push rod. l Unscrew and remove slave cylinder mounting screws and pull out slave cylinder.