Gregory Bender
Gregory Bender
Gregory Bender
 

2013 March 19: Install the flywheel and clutch

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Time to fit the flywheel. Note the casting mark I am pointing to.
Time to fit the flywheel. Note the casting mark I am pointing to.

Photo courtesy of Gregory Bender.

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Note the white mark on the crankshaft.
Note the white mark on the crankshaft.

Photo courtesy of Gregory Bender.

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Note the two align. This indicates the crankshaft is at TDC for the right cylinder.
Note the two align. This indicates the crankshaft is at TDC for the right cylinder.

Photo courtesy of Gregory Bender.

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Now examine the flywheel. There is an arrow.
Now examine the flywheel. There is an arrow.

Photo courtesy of Gregory Bender.

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There is a line.
There is a line.

Photo courtesy of Gregory Bender.

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There is a D.
There is a D.

Photo courtesy of Gregory Bender.

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There is another line.
There is another line.

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There is an S.
There is an S.

Photo courtesy of Gregory Bender.

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The arrow must align with the casting mark.
The arrow must align with the casting mark.

Photo courtesy of Gregory Bender.

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The D will be visible through the corresponding hole in the transmission - very useful when setting the ignition timing!
The D will be visible through the corresponding hole in the transmission - very useful when setting the ignition timing!

Photo courtesy of Gregory Bender.

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New flywheel bolts and Schnorr washers. I use blue Loctite on the threads.
New flywheel bolts and Schnorr washers. I use blue Loctite on the threads.

Photo courtesy of Gregory Bender.

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The flywheel is secured in place.
The flywheel is secured in place.

Photo courtesy of Gregory Bender.

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Set the engine on it's nose and fit the springs.
Set the engine on it's nose and fit the springs.

Photo courtesy of Gregory Bender.

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Fit the pressure plate. Note that the dot on the tooth must align with the arrow on the flywheel. Doing so is necessary to make sure the springs fit into the approprieate recess.
Fit the pressure plate. Note that the dot on the tooth must align with the arrow on the flywheel. Doing so is necessary to make sure the springs fit into the approprieate recess.

Photo courtesy of Gregory Bender.

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With the pressure plate in place, I stick my finger in the hole and verify that each spring is properly seated. I've never had problems myself, but I had to repair a bodged clutch job made by a well known shop because they had failed to ensure the springs were seated properly. The clutch did not function correctly. The shop refused to redo their work or even recognize that the clutch clearly did not function properly. Unbelievable.
With the pressure plate in place, I stick my finger in the hole and verify that each spring is properly seated. I've never had problems myself, but I had to repair a bodged clutch job made by a well known shop because they had failed to ensure the springs were seated properly. The clutch did not function correctly. The shop refused to redo their work or even recognize that the clutch clearly did not function properly. Unbelievable.

Photo courtesy of Gregory Bender.

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I use this tool to compress the pressure plate and align the clutch plates. Historically, I've used a variety of tools to get the job done. But, I like this tool sold by MG Cycle best.
I use this tool to compress the pressure plate and align the clutch plates. Historically, I've used a variety of tools to get the job done. But, I like this tool sold by MG Cycle best.

Photo courtesy of Gregory Bender.

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I fit this tool to prevent the flywheel from rotating while I tighten the pressure plate tool. This tool is useful for several other jobs, too. Again, I've held the flywheel by many different methods historically. But, having the right tool is nice - this one sold by MG Cycle.
I fit this tool to prevent the flywheel from rotating while I tighten the pressure plate tool. This tool is useful for several other jobs, too. Again, I've held the flywheel by many different methods historically. But, having the right tool is nice - this one sold by MG Cycle.

Photo courtesy of Gregory Bender.

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Fit a clutch plate; splines protrude toward the rear.
Fit a clutch plate; splines protrude toward the rear.

Photo courtesy of Gregory Bender.

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Fit the intermediate plate; placement does not matter.
Fit the intermediate plate; placement does not matter.

Photo courtesy of Gregory Bender.

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Fit another clutch plate; splines protrude toward the rear.
Fit another clutch plate; splines protrude toward the rear.

Photo courtesy of Gregory Bender.

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Fit the ring gear.
Fit the ring gear.

Photo courtesy of Gregory Bender.

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I use new bolts and Schnorr washers to secure the ring gear to the flywheel.
I use new bolts and Schnorr washers to secure the ring gear to the flywheel.

Photo courtesy of Gregory Bender.

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Here is the flwyheel fully assembled.
Here is the flwyheel fully assembled.

Photo courtesy of Gregory Bender.

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For reference, I used these clutch plates from Stein Dinse (sold by MG Cycle in the USA).
For reference, I used these clutch plates from Stein Dinse (sold by MG Cycle in the USA).

Photo courtesy of Gregory Bender.

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A close up of the box.
A close up of the box.

Photo courtesy of Gregory Bender.

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