Clutch assemblies - inspection

10. Blank off one of the oil passages in the clutch drum with clean, lint free cloth.

WARNING: Do not use fingers to blank off oil passage.

11. Apply low pressure air to the remaining oil passage and expel the clutch piston.

12. Remove piston, remove and discard 2 ’O’ rings.

Clutch assemblies - inspection

1. Thoroughly clean all components, ensure all oil passages in clutch drums are clear.
2. Check clutch drums for scoring and corrosion, light corrosion may be removed using grade 600 emery cloth soaked in gearbox oil.
3. Check clutch plates for signs of overheating and wear, plates which are discoloured or worn must be replaced.
4. Check clutch end plate thickness: 1st clutch = 1.55 to 1.65 mm 2nd, 3rd, 4th and 1st hold clutches = 1.95 to 2.05 mm

CAUTION: Clutch plates must be replaced as a set.

5. Check clutch discs for wear, the grooves in the face of each disc must be visible and of equal depth.
6. Check clutch disc thickness: All clutches = 1.88 to 2.00 mm

CAUTION: Clutch discs must be replaced as a set.

7. Check return spring free length: 1st clutch = 29.0 to 31.0 mm 1st hold clutch = 32.6 to 34.6 mm 2nd, 3rd and 4th clutches = 28.5 to 30.5 mm