8-0249VDF

Clutch kit fitment procedures:

Minimum Fitment Requirement:

This product should only be fitted by a qualified technician. The manufacturer’s service manual must be followed at all times – do not attempt a clutch replacement without the manufacturer’s service manual.

Pre-installation:

Inspect for Leaks: Check the gearbox and engine for oil leaks and promptly address any issues.
Check Mountings: Ensure the engine, gearbox, and prop shaft mountings are in good working condition.
Inspect the Release Fork: Disassemble the release fork, including pivot points, and check for wear. Replace worn components with Original Equipment (OE) parts.
Examine the Gearbox Sleeve: Inspect the sleeve that the release bearing slides on for wear. If replacement is needed, ensure all surfaces are thoroughly cleaned.
Verify the Input Shaft: Check the gearbox input shaft for wear and ensure it fits securely into the pilot bearing. Replace the input shaft if wear is detected.
Check the Hydraulic System: Disassemble the hydraulic actuating system and inspect for damage or wear. If needed, replace the cylinder with either an OE cylinder or a Hydradrive cylinder.
Replace the Clutch Cable: If the release system is cable-operated, always install a new OE clutch cable—never reuse the old one.
Clean Critical Areas: Ensure all dirt is removed from the gearbox bell housing and the flywheel side of the engine. Any remaining debris can contaminate the clutch and void the warranty.
Inspect the Bell Housing & Engine Flange: Check for damage or burrs and repair as needed. If dowels are damaged, replace them.
Machine the Flywheel: Always resurface the flywheel when installing a new clutch. The friction surface must be free of hot spots, scoring, and cracks. Before removal, measure runout—it should not exceed 0.1mm.- If the runout exceeds 0.1mm, replace the flywheel. After machining, recheck runout. If it still exceeds 0.1mm, replace the flywheel.

Installation:

Torque Flywheel Bolts: Always torque the flywheel bolts to the manufacturer’s specifications.
Check Flywheel Runout: Use a dial gauge to verify that the flywheel runs true and does not exceed acceptable runout limits.
Install the Release System Correctly: Avoid applying pressure to the bearing side of a concentric slave cylinder, as this can damage the seal due to insufficient lubrication.
Follow Model-Specific Fitment Procedures: If a concentric slave cylinder is used, install it according to the service manual—some models require a specific procedure.
Remove Oil Contamination: Ensure all oil is completely removed from the flywheel and pressure plate friction surfaces before installation.
Replace the Pilot Bearing: Always install a new pilot bearing and ensure it is fitted correctly.
Prevent Oil Contamination: Keep oil away from the clutch disc’s friction surface, as contamination cannot be cleaned and will require disc replacement.
Tighten Cover Assembly Bolts Properly: Secure the cover assembly bolts in a diagonal pattern, tightening half a turn at a time. This prevents cover distortion, which could lead to uneven diaphragm fingers, poor clutch release, and clutch shudder.
Align the Clutch Disc: Use a spigot shaft to perfectly align the clutch disc during installation.
Ensure Smooth Gearbox Installation: Support the transmission with a gearbox jack, align the input shaft with the disc splines, and slide the gearbox bell housing onto the engine smoothly. Tighten the bolts securely before removing the gearbox jack.
Adjust Free Play & Pedal Height: Set the correct clutch pedal free play and height according to the manufacturer’s service manual.