1. Getting
it right the first time. It is vital to diagnose
the cause of clutch malfunction before the clutch
replacement, ie check hydraulic system - bearing
free travel - clutch cable, oil leaks and check
for any signs of red dust when old clutch is being
removed. Any or all of these problems must be
corrected before installing new clutch.
2. Ensure
clutch supplied is correct for the application.
If you're unsure, call Martin's Clutch and Brake
for advise, as fitting a clutch to the wrong application
will void the warranty.
3. Flywheel
must be resurfaced or warranty void and check
pilot bearing or bush and replace if necessary.
4. Before
fitting, check clutch for any shipping damage.
Next, check that the clutch disc slides freely
on gearbox shaft and then clean shaft splines.
Lightly grease the shaft with high melting point
grease. Always ensure bell housing is degreased
and is free of dust and that fibres from the worn
clutch are removed.
5. Check
the clutch release fork for cracks, check the
clutch cable for stretch signs and check the release
bearing gear box quill/gear box main drive nose
cone bearing slide for any wear. Always lightly
grease this part where the bearing slides. This
will allow smooth sliding of the bearing carrier.
Always work the fork forwards and backwards after
installing bearing on the quill.
6. Place
the clutch cover pressure plate assembly over
the clutch disc, after checking that the disc
is the right way around and the bud section of
the disc does not foul on the casting of the clutch
cover assembly or the flywheel. A suitable clutch
aligning tool will ensure correct alignment, assist
in ease of installation and avoid spline damage.
(Burrs on splines are a major cause of difficult
gear disengagement). Ensure pressure plate dowels
are aligned to the cover. Tighten bolts in a diagonal
pattern and never use air tools to install a clutch
cover assembly.
7. Re-fit
gear box, taking care not to bend the clutch disc.
Never hand the gearbox off the clutch disc or
use any force to align gear box shaft.
8. Check
all bell housing dowels are in correct position
and tighten bell housing bolts. Ensure there is
no dirt or foreign material between the mating
surface and the bell housing.
9. Perform
any clutch adjustments only to vehicle manufacturer's
specifications.
10. Always
check the clutch cable if you are unable to obtain
disengagement when a new clutch is fitted. Start
off your checking process by replacing the cable
and checking hydraulic system.
11. Road
test vehicle and never abuse a newly fitted clutch.
Allow 1000 km run in and always adjust free travel
on your new clutch at 1000 km and 3000 km. Thereafter
adjust at every 10,000 km.
