Clutch checks

[carphone]

Hi all, has anyone replaced the clutch on an 04 twinspark yet or got an 04 onwards manual?

The clutch has 7 plates instead of the previous 8 and the manual I have does not list the correct dimensions for checking the lined plate and clutch pack thickness. I need the updated dimensions.

Also the pressure plate seems to have about 2 mm of wear / recess on the friction face. Is a new pressure plate recessed on the friction side or is it flush?

There is nothing wrong with it but I want to check it all out while I am replacing the water pump, which coincidentally was not leaking but on inspection wear was evident and it would not have been long before it started.

Thanks
Mike.

 

[richc]

I've got the repair manual in a .pdf file. Give me an email address and I'll try and mail it. It's big. They're available on Ebay over here for under $10 including shipping.

 

[carphone]

Hi, thanks for the reply. I don't think my mailbox has that kind of capacity but if you wouldn't mind looking up the clutch dimensions for me It would be much appreciated.

In the old manual there are two dimensions, one for total clutch pack thickness and one for lined plate thickness only.

Many, many thanks
Mike.

mikf650 (at) yahoo (dot) co (dot) uk

 

[richc]

Wear limits:
Distortion of lined plates mm (in) 0.25 (0.010)
Distortion of steel plates mm (in) 0.15 (0.006)
Total height of lined plates mm (in) 27.5 (1.08)
Total height of plate assembly mm (in) 39.1 (1.54)

Torques
Engine block cover, left ................................ 10 Nm
Drain plug for water pump........................... 10 Nm
Oil line to cylinder head.................................. 8 Nm
Oil line to engine block................................. 35 Nm

A bit futher into the procedure, they've got this chart.

Measure the height of the 8 lined plates when
pressed together.
• Height of complete compressed plate cluster.
Height of lined plate
cluster ..................................min. 27.5 mm (1.08 in)
Height of complete plate
cluster ..................................min. 39.1 mm (1.54 in)
Lined plate distortion................. 0.25 mm (0.010 in)
Steel plate distortion ................. 0.15 mm (0.006 in)

If these aren't what you need, let me know. I should be able to just copy the clutch section and email it to you. They've got a lot of info in there about taking the temp (?) and using loctite in various places. I'm not a mechanical sort so none of it makes sense to me.

 

[carphone]

That looks like just the job.

Many thanks, your help is much appreciated.

Mike.