4.6 ServiceManual-RocketIll

ClutchCover

Removal

Clutch

Removal

1. Removetheradiatorasdescribedonpage

12.11.

2. Removethewaterpumpasdescribedonpage

12.7.

3. Removethecoolantpiperunningbetweenthecrankcaseandwaterpump.

4. Disconnecttheclutchcableasdescribedonpage4.5.

5. Releasetheringofbolts securingtheclutchcovertothecrankcases.

6. Place anoilcatchtraybeneaththeclutchcovertocollectanyoilthatmayspilloutonremoval.

7. Carefullywithdrawthecoverdisengagingthelifterarmasit iseasedforward.

Installation

1. Thoroughlycleanthecoverandcrankcasematingfaces.

2. Positionanewgaskettothecrankcase.

3. Refitthecoverensuringthatthegasketdoes notbecomedislodged.

Note:

• Ensurethat thelifterpieceengagescorrectlywiththelifterarmduringassembly.Itwaybenecessarytopullthelifterarmforwardtoallowassemblytotakeplace.

Fitandtightentheboltsto9Nm.Tightentheboltsinadiagonalsequence.

Refitthecoolantpipe,tighteningitsfixingto9Nm.

6. Refitthewaterpumpasdescribedonpage12.8.

7. Refittheradiatorasdescribedonpage12.13.

1. Removetheclutchcoverasdescribedonpage

4.5.

2. Undothe bolts,withdrawthespringsandremovetheclutchpressureplate.

1. Pressureplatebolts

2. Springs

3. Pressureplate

3. Removethelifterpiece,needlebearingandthrustwasher.

1. Lifterpiece

2. Needlebearing

3. Thrustwasher

ServiceManual-RocketIll ^4.7

4. Removealltheclutchfrictionplatesandsteelplatestogetherwiththeanti-judderseatwasherandspring.Notetheorientationofallcomponentsastheyareremoved.

"'""

1. FrictionPlates

2. SteelPlate

3. Anti-judderSeatWasher

4. Anti-judderSpringNote:

   • Theinnerandoutermostfrictionplatesaredifferenttotheremainderandarealsodifferenttoeachother.Theymustnotbefittedinanyotherpositions.

   • Refer tothefollowingpageofthissectionfordetailsofclutchfrictionplateinspection.

   • Itisnotnormallynecessarytodisassembletheclutchfurther,butiftheclutchinnerandouterdrumsaretoberemoved,proceedasfollows:

5.Engageanygearandlocktheinnerandouterclutchdrumstogetherusingservicetool3880025-T0301.

1.Servicetool3880025-T0301

6. Depresstherearbrakepedaltopreventtheenginefromturning,and thenreleasetheclutchcentrenut.

7. Removethecentrenut,Bellevillewasher,plainwasher,clutchinnerdrumandthrustwasher.

1. CentreNut

2. Bellevillewasher

3. Plainwasher

4.InnerDrum

5.ThrustWasher

8.Slidetheclutchouterdrumoutwardsfromtheengine,collectingthebearingsleeveonremovalofthedrum.

1. Outerdrum

2. Bearingsleeve

4.8 ServiceManual-RocketIll

FrictionPlateInspection

Thickness

1. Ifanyfrictionplatethicknessisoutsidetheservicelimit,replacethe frictionplatesasaset.

1^-.ClutchfrictionPlate

Frictionplatethickness-allplates
Standard	3.72-3.88mm
Servicelimit	3.5mm

2. Checkallplatesforbendandwarpasfollows:Placetheplatebeingcheckedonacleansurfaceplateandattempttopassafeelergaugeofthemaximumservicelimitthicknessbetweenthefrictionplateandsurfaceplate.Ifthefeelergaugecanbepassedbeneaththefrictionplateat anypoint,renewtheplatesasaset.

1. FrictionPlate

2. FeelerGauge

3. SurfacePlate

Assembly

1. Positionthebearingsleevethentheclutchouterdrumtotheinputshaft.

2.Aligntheoilpumpdrivepegswiththecorrespondingholesintherear oftheclutchouterdrum.

1. Clutchouterdrum

2. Oilpumpsprocketdrivepegs

3. Oilpumpdriveholes

• ServiceManual-RocketIll

4.9

3.Pre-loadandaligntheprimarygearandbacklasheliminatorwiththecrankgear.Alignthegearsthroughtheholearrowedbelow.

1. Primarygear

2. Backlasheliminator

3. Crankgear

4. Arrowed;alignmentholeNote:

   • Whentheouterdrumiscorrectlyfittedandthegearsarepre-loadedcorrectly,thebearingsleevewillbeaflushfitwiththeclutchdrumface.Inaddition,agroovearoundtheinputshaftwillbevisible.

4. Fitthethrustwashertotheshaft.

1.Thrustwasher

5. Fittheclutchinnerdrum.

6. Refittheplainwasher,fitanewBellevillewasher('out'markfacingoutwards),andrefit thecentrenut.

1.BellevilleWasher'Out'Mark

7. Locktheinnerandouterdrumstogetherusingservicetool3880025-T0301.Depresstherearbrakepedaltopreventtheenginefromturning,andtightentheclutchcentrenutto105Nm.Removetheservicetool,

1.3880025-T0301

7. Disengagesecondgearandcheckforfreerotationoftheclutchinnerdrum.

8. Coatallclutchfrictionplatesincleanengineoil

9. Fitthefrictionplates,steelplates, anti-judderseatandspringtotheclutchbasket,inthesameorderasnotedduringremoval.

Note:

• Theinnerandoutermostfrictionplatesaredifferenttotheremainderandarealsodifferenttoeachother.Theymustnot befittedinanyotherpositions.