B2BG19K1 - 607 ML5T GEARBOX

REMOVAL - REFITTING CLUTCH

1 - SPECIAL TOOLS

[1] Clutch plate centralising mandrel (-). 0216-C .

[2] Clutch stop removal tool, (-). 0216-D .

[3] Clutch stop re-fitting tool, (-). 0216-K .

2 - REMOVAL

Remove :

• the gearbox
• the clutch mechanism
• the clutch plate

NOTE : mark the relative positions of the clutch and flywheel (in case of re-use of the cover), the clutch release stop remains clipped to the mechanism .

EW/DW ENGINE

Remove the ring (1) without deforming it .

Extract the clutch stop .

Refit the ring (1) to the stop (2) .

ES9J4S ENGINE

Remove the clutch release stop (3) using the tool [2] (used to compress the clip ring) .

Press on the mechanism to unclip the stop .

ALL MODELS

3 - REFITTING

Visually check :

• the flywheel face for damage or scores
• the flywheel for wear
• the condition of the starter ring gear

If oil is present, replace the crankshaft oil seal .

Follow the direction of fitting, With the larger flange (A) of the disc on the gearbox side .

Fit the mechanism and centralise the friction plate using the centralising tool [1] .

Tighten the bolts to 2 daN.m .

Apply a small quantity of MOLYKOTE BR2 PLUS grease to :

• the stop guide tube
• the 2 fork supports

ES9J4S ENGINE

Check that the clip ring (4) is in its groove, covered by the plastic ring (5); if it is not position it correctly .

Remove the ring (4) from the stop .

Remove the plastic ring (5) .

Place the plastic ring (5) in the tool [2] .

Refit the stop ring (4) to the stop .

Cover the ring with the two semi-circular rings .

Offer up the stop to the tool, holding in place the two semi-circular rings .

Press on the stop .

Remove the stop from the tool [2] .

Remove the two semi-circular rings .

Check that the plastic ring covers the stop ring .

ALL MODELS

Coat lightly with MOLYKOTE BR2 PLUS grease :

• the release bearing guide sleeve
• the fingers of the fork

Position :

• {{o70906}} les becs de fourchette dans les crochets de la butee

Fit :

• the clutch stop to the input shaft guide tube (4)

refit the gearbox .

Reclip the clutch stop :

• insert the tool [3] in the oblong hole in the clutch fork
• rotate the tool [3] by 90 °
• pull, using the handle, to clip the stop
• check that it is correctly clipped by pushing the tool (the stop should not fall back)