FORD CAPRI 1974 Owners Manual

Monsurin g plug gnp . gaugo ;;:;;;-;;;"",,',,"," ignition sysICm spccilicalions) should have a sliUht 'drag' when slid between the olocuuch~s. Adjust {[liP if necessary
N orm al. r, dcpo~il~.liUlolly coaled corc nose. increasing by around 0.00 1 in (0.025 mm) pc, 1000 miles (1600 km). Plugs ideally suited to en\j ine. "nd engine in good
condition
Oil fouting. Wet. oily dr~pOl;its. cal,se eventually misfirc. Fllult : wmn bores/ilision 'ingSOf valve guidcs: sometimes OCC"'!! (temj.lO'Hrilyl d .. ring lunning-in
poriOd. Plug~ C()I1 IJ() H! u~ecl "ftc. thorouUh cleaning
-," ..
. \\'
in Electrode demoge. ;;;;,:;;;;;;;:;;;~;~;';::;;i ;;,,, ",,;; h;,
bumed, glazed appearance. Fa ult: pre')gnohon Check: as 101 'Overheating' bllt may be more sovero. Discard plugs ar1d rornedy fault belorc piston or v31vc d~",age occurs
.'
.. ", . ~,'''':c." ~~:~~~~~~::i, Adjusting plug gap. Tlu, plug gap is, 03rth electrode inwards, or oulwards, as I correct clearance is uillaim!d. NOlO II,,! use 01 tho COlfcct tool
spark ami I I' Chock: cMhulOllor , • sellings, 1I0al level ,lIld iot siles; c hoke (lJlOla lion .mel cltlanli n()ss 01 ai, fillel. Plugs can bo rc­usod :"1 Overhoating EI()cuud'ls h,lVO \Jlilwd ~ppcaf3nce, CO'O noso vely while lew dello~iIS. f;I!I't Ilh,O uvelheatinu. Chec k: plug
vlJlue, iunitiun limill H. I"clu t;lillle I1Itillu (tOO lowl mixture lWQ w('ak). DisC , ,.
i Split cor o noso (mny npllollI i 8 crBck). Damage is
sel f.evide nt, bUI cruc ks will only showalter cloaning. Faul t: pre­ignition 01 wrOIl!) !)ap settin!) technique. Check : ignition liming,
cooling SYStCIl1. 1",,1 O C t;"" .. r alin!) (too low) and fuel mixlure lton woak) . Discilld "Iu!)s. ",Clllv laul t immediately
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Chapte r 4 Ig nitio n sys te m
6,SA Unsc rew the clamp bolt, 680 ... and remove the (tistJlbu to. 68C Rotor nnn alignmen t ;]lter re movnl Irorn engine
~ I
~.

F ig . 4.3 IU "i\iol1 timinu ma,ks o n the 3,0 lit.e e:1Uine (Sec 6)
Allow ;//(lic<1leS din'cliu" 0' !(JIM;oll
7 Distributor (3.0 litre engine) -overhaul
W,th the diMJlhuto. removed from the entl,ne. 'emove the rotor arm and the cont.1CI breaker assembly . 2 Prose Ihe small Clfclll} I'om the v"cuum u,,,t p,vo l IXJSt. 3 flemove th e two sc,ews wh,ch sucure the hfllaker pl,lI!! to Ihe d,slJlbu tor body and hit the ,}I'rte orl.
" Slacken Ihe self'lappmg SCfew which SC<:UlCS the condense, and low tenSion leads 10 Ihe contact l .. eaker a ssembly and shde OUI Ihe lo.ked ca ble terminations, 5 Undo imd remove Ihe condenser rCI.1,nlfl!.l screw and remove the condense •. 6 Remove the c" chp. lIiJt washer and wavy wash er from the pivot post. Se parat e the two plates by h,ingmu the holding down se,ew Ihrough Ihe keyhole sial in Ihe lowe. 1)late , Ta ke care not 10 lose the e.Jrt h spring on the prvo t flOst. 7 Remove the two se,ews seeu"n\) Ihe vilCuum un,t to the d IS t"lHIIO' hotly .Jntl remove the vacuum uni t. S To d,snl.JllIle Ihe vacuum unll, remove the plug I.om the end 01 the
unit (md withdraw the spring. vacuum stOp and shims 9 Oelo,e disll1<1ntling th e centJllugal .Jtlvance mech.Jnism. note thM th e tw O spri ngs arc d.lle.ent and ma,k them so th.Jtlh ey .Jre ref'tled in th ei r OJlgHlall}lilces . Remove the sp. ings. pJlse all the circ lil)S securong the cenlJlluga i weights. nl.J.k the weight s 10 'dent'fy their o"ginal positions and then remove them ,
1 0 M3 lages w llh the s tol) m Ihl! ;]C hOn I)I"le II II" s IS not dono. II rs ~ s, llle to h.Jve th e ,oto, ,'Jln 180' from 'I S COf/,-ct pOSition. 11 Remove the lelt pad 1 10m t h e centre 01 the C.JIll. e~pand the circhp
x - ------:::-.
z
y -
Fig . 4.4 Distrihutor lilting position on the 2.8litrc e ngine (Sec 6)
XX Re.1r "U;,.' of ellgmc yy V,1CI/(JIII flllil Mas Z = 0 '10 11/'
A Triggcr (lffll U Slillor l!fII!
whICh'S Ihen exposed Ilntl ,emove ,I L,lt all Ihe Ci"n and 1l(IV3ncc plJle ;Issemul y,
12 Do nOI .cmove t he d,stJluutor Sl)indle unless II 's necess.l'y to "1 a new ge.n. 0' S I)iJldle To remove Ihe uear . usc <1 IlUnch Ilnt! hJmmer t o dJlve outlhc lock P'" and Ihon pull tl)() !.Ic", frO'11 Ihe sprndle T"ke cn,e
1 0 rOIil'" ilny slums, 0' wllshe,s wh,ch fll.Jy be In led . W,t h the ueJ' lell'Ov\:(\. the sl)lIldle .Jsscmbly can be withd,awn hom the d ,s'Jlhu tor 13 Belore reassembhng. ca,elully clc.J1l the body 01 th e d,s lnbulOr and "II a s CO'llpo llent p"'ts. II th e sp,n(!ie has been .emoved. lulmenlC II w'lh e'lu",e oil h efor e ,ellssemhly. 14 Reassenlbly.s <1 SUa'ghtIOrw<1Jd ,eve'SilI 01 d,sman tling bUI t he,e Inc several pointS which shoold be noted.
15 Lut)JJc;]te th e ce Jltlil ugnl weights and otho. p3rtS ol the cenlrifugal
advnnce mechanism. the diSlrrbutor shah a nd Ihe pa'l 01 the spindle wh,eh c.l"'es Ihe cam assembly. using engine all. Do not orl excess,vely. 16 " Ih e dr'veshnlt hilS heen .emoved. firSt re fi t th e thru st wash ers below tho action plnte. bolore "'se,ting the S h .l h into thc disl. ih llto,
hody . FII the w3vy washer .Jnd IhrUSI washcr to the lowe! end 01 the shah and then relilthe ge.Jr. secuJlnU it with a new spring p in. II a now gear. or a ne w u"ves hnfL h,15 been fllt ed . a n\lW hole should be d"lIed .1t 90' 1 0 Ihe e~is'U1g hole 17 Alte • .Jssemhhng the centJll ug.J 1 weIgh ts .Jnd sprrngs. check that Ihl!Y movo hccly. w,thout I)inding, 18 8clOle assemblmg Ihe breaker pla tcs . make sure thill the three nylon bearing slUds a.e located "1 tht) h oles ,n the uPllC' uearinU plale and Ih3tthe e.Jrth,ng sprrng ,s foiled to the p,vOt post 19 On complet'on of assemlJly. adlust the conlnCl b'eake , gilp to the spc cified selling
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Chapter 4 Ignition system 93
8 Distributor (2.8 lilre engine) -overhaul
There arc only two overh"ul jol)s possible. these being the fitling of a t"UUcr carl krtllnd the renewal of the vacuum advance uni\. Excessive
I -
Fig. 4.5 Exploded view 01 the distrihutor fitted to the 2.6 litru cnginc (Scc 6) 13
, DIS/111m/or Cill' 2 HOIQ'lIrm 3 Du,~1 covtJr 4 Rolf I,m , Clrchjls 6 T,iY(Jt'f ,1m! ,lssl.'ml!l y 7 Tii{Jllt'/ coli 8 SWim 9 Sc/ow
'"
BaSOI/Mlo
" SCIOW
"
a·rillg
'"
SCIOW
" Vacuum ullil
"
Dis/li/)uiQl body
'6 Ch,1 c/.ll11/1
"
Clip
weM or dllmage to the distri butor body or drivesh"ft wrll I11C r enewal of thO complete distributo •. 2 Refer 10 F'g. 4.5 fo r the order of fomov ~
, @---3
1j---4
~__6
~--5
~
-7
'" ~ ~ .
~-5
8---~ ,::::. -;:.
I .J
U-9
® -IO
II_--g
--15
iltjL" ,
~~-12
16
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94 Chapter 4 Ignition system
i ' .
. --8 2A Removill{J the IllnSlre dust COve, (28 hl'c Cllume)
./ :,
, , ,
(\. I ,
" 'v
J 2C W'''I1!j connector i'Uld seCUJlIlg screw (lHOwS)
9 Ignitio n timing -adjustment
Wnh the (.lIs\"OuIO' III!Cd ilS dcscllbed OIl SectIon 6, check Ihilt 1Ill! COHCCt llllllng m;l!ks "'0 ;1119110d. 2 To check the ;1111,,11 (5 t;1I,e) setting, .emovc the (I'51"lIu I0' c;lll [11l\( check IhJllhc rOl0' ;lIm IS PO"1I1119 to the No 1 cylmdc. scgmon!.n the Cill) rndlcmed by the sial on the 11m. 3 On the 3.0 lUre engIne the cont,le l poullS ll\u~1 he ,ust SCI)ilril\U'!J Tho e~ilCt Instant C,1" he checked by connect"'u il 12 vol1 lest lamp between the contilC, brcilke r low tenSIon Iemur),,1 iUl(t O,"lh, W,th the iUnilion Oil, tho d is trlbuto. ShOllld be turn ed nrl\,·clockwisc unlol lho bulb luSlligh(s. " On (he 28 li(re enuule the ("gger arms and stator ;HIllS must bc aligned It not. (um I he (hst"bulOr as necessary . !:i Tighten the (hSI"buto. clamp boll and .ehl the cap 6 Set In thIS way the lUlling WIll be alll)'Olmalely co , ..
8 2B UtJlle. vIew 01 the l.imJer Mrn .lrld Call (28 lIt Ie enU"Wj
.1
,I,
.. .."
8 20 Vacuum un.1 sC(:u"ng screw WIth e')Hh lead termmal
10 W,lh Ihe enij1l1e I(lIrng pornt thc \fmlng hgh( at the cr",lksholl1 pulley The wh,le 1),1mte hne
12 To check the mechanrcat adv.1nce. Increase the engIne speed and note whelher the wh,te malk on the pulley moves away Irom the mark on th e pOInter . 11 It docs the mechanical advance is lunctioning 13 W,th the enOlile Idlmu the vnCU\ Jm advance can be checked by suc kIng the oldv~ncu pIpe that W.1S removed from the carburellOI o r air box ThIS should also c.Juse the while rnark on the pulley to move away horn the mar k on the pointer 14 On completIon remove Ihe timlllU hght and rC(:onnec lthe v.1CUUIll pIpe
10 Ignition illlllllifier module (2.8 l i tre enuine) -removal and rClittinu
Thc Iunitlon illl\J}l lflcr module is locmed on Ihe left· hand SIde of the engIne COnlpar tment. tUSI behind Ihe hOnt suspenSIon strut upper mounting.
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Chapter 4 Ignition sys te m 95
)
) .. . '.
. 2 1!11"I'On ampllf,er mod"l~ .1m1 mull< .pluu eOllllecto,s
2 With til() l~pll!lOn sw'tehud off rhsconner.1 thO two llIulu·plu!) comW(:I 11 Spark 1)lugs -re m oval, servicing and retitling
l' Rem ove the ilir clea ner or inl et duCling ilS rC{luuC tl. 2 Identify Ih c HT leads for posi lion \hen c11Se 0I1I1CCI them from thc sp.,.k I)I!I!J$ hy plllhn!) on the IC'fl,i",11 ends. not Ihc tIIilin leilds (photo) 3 US'''!! a sp;"k pluy Sl)ilnnrlr. unscrew tllf! pluUs 1'0111 the cyhnder
h
Ci'ld s (ph"lo~1 4 H Ih'l IIl',,,laIOl no~ of Ilw sp",k pl"H IS dean i'lnd wh,te. wl1h 110 (ICPO$115 tlw;.~ ".dlCo1l1ve of a w,~;,k n"~IUH1. 0' 100 h o t .1 plug (,1 hot plug II;'n~h:ts 1",.11 aWily fWIl' t he I)h.~:I.odc slowly il cold I lhl!1 triHl sle.s ,I ;rw.lY "",dly) <; lhl! IIltl!JS f'l1l:d ilS stimrJi"d a'c ilS hSICd IIllhoJ S pccifleallol1s!lt Ilic ha. d black look",U depos.ls. th..,,, Ih .s .s ,mheilhve Ihilt Ihe m'~I\I.e IS o "eh Should Ihe plllg he h l"ek amI Oily. Ihen II IS lik ely thaI the .I U ine IS fairly W Olfl. (IS well il~ Ihe mixilne benlU 100 Itch 6 If th c lllSuliltor nose '5 cove.ed wnh I I\Jll t Ian 10 glcY ls h blown (ICI>oSIIS. Ihen Ihe mlxllue's CO"I..'CI ,lnd II '5 h kely Ihallhe eng"'e IS ill good condurOll 7 "the.c ilfC illly Iraces of lo"g b.ow n tnpC""1J stilU'S onlhe OUlslde 0 1 Iho wh'le pOl lion ollhe plug. the n th O pl\l\: 1 W ill h,1V(l1O be renewed.
as Ihis shows Ihiltlhere .s il filulty Jom l helween Ihe plug ilnd body and Ihe insulilIO '. and comp. ess.on .s beltlU ilflowed co IC 3
4 \)6
Fig. 4 .6 HT I Cild l)osilion5 o n the 3.0 l i tro C "~Jine (Soc 11)
AllOW III'''(;,lICS ,,,,,,1 ul "'''UtllC
Fig. 4 .7 HT lead posit io ns 011 Iho 2.8 lilro engino (Sec 11)
AllOW imilc,lles I'UII ! 01 ell!}"''''
8 Plugs should be clCilned by.1 So,,,(1 hlilsung n'achme w hich w.lIl.ce thcll' from cil.bon mo.e Iho f
enewcd.
~. . -,,' ;-------
..... -.,.""I'~ -, .. C"
-C~i < , ','" , ,., :.."
.---.
. ~~ ' . ." , _ t~ .
,
I • I 2 DlSCOllllCC I thO lIT leild . 11.3A ... unsc.ew the spa.k plug I I 38 and remove 11
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,6 Chapter 4 Ignition system
9 The spark plug gaf} is 01 conside rable impor1~e. as. if it is too lilrge or too small. the size of the spark ilnd its efficiency will be seriously impilired. The spilrk plug should be set to the ligure given in thl} Specifications ill the beginning of this Chapter; IOTa sel it, measure the gilp with a/cere, gauge. and then bend open. or close. the outer plug electrode untillhe correct gap is achieved. The centre electrode should never be benl as this may crack the insulation ilnd cause plug fAilure if nothing worse. 11 Relit the plugs, and re/ilthe leads from the distr ibu tor in the correct I"ing order. which is given in the Specifications. Screw the plugs in by hilnd initiilily then tighten them to the specified torque using the plug spilnnel.
12 Fault diagnosis -ignition system
By lar (he nlo1jori (y 01 brCJkdown and running troubles ilre caused by InUits In the igrlOlron system er(her in (he low (enSlon or high tens ion circuns There LJratlon or fuel Injec tion Setlln(Js, ilre normally tllle to faults in the d,strrllulOr Or 10 Incorrect I(Jrlltion tlllllrl!J .
Engine fails 10 staft 1 If the engine falls to StM( and t he cal was IIJnning norll1t1l1y when.t wns IJst used, first check ther e is fuel in the petrol wnk. If (he engille tums ovel normally on (he starter 1I10tor and the bilHery is evidently well chmged. then the lault mny be in either the high or low tension circuits. Firs( check Ihe HT circuit. Note: If lire hal/cry is known 10 hI! {(Illy ch,}lged, Ihe ignilion liglll cOllies on, ,1I)d Ihe s/arler 1II010r {,lils /() tum IIIe ongine check the tightness o f the le'lds on the biltlely terillinilis ,1I)d <1Iso (lte seCUIIHWSS oflhe e,l,th leold (0 irs cOllllec/ion 10 tire body It is qui(e common for tlie le,1(ls /0 Ii,}ve wOlked loose. l.'vc'1I If Ihey look ,1n(/ lecl seclI,e. /I one 01 the boll/my ((:{minM {Josts [11.'1.1' vC'IV liot wi".." (Iyiny (0 wOlk Ihe s/mler 1II0tOl (his is ;/ sUie IIId'C,7/IUI/ 0/ ;/ I;wlty COllllel;('On 1(1 1h.11Ie"lIillal. 2 One of tile commonest rOilsons lor bad stmtln!J IS wet or d;UllP sp,uk plug lead~ and dlstribu(or. Hemove (he distllblltor cap. H "JOdenSil(Ion is v iSIble IIlte!llillly dry the CJp With il rag and also wIpe ;lCf the leads nelu the cap_ 3 If (he enUiue sull fmls 1 0 St.l.t. check that cunent IS reachlllg (he JUS, by dlscounectln!1 ench plug le,l<1 in turn ilt the sp1Hk plllU end, .. ,ld holdlllg Ihe end olthe callie about 5 mm (0.2 Ill) aWilY from the cylillder block. Spin the enu'ne all the sta rter motor. 1 Spa,klllg between the end of the cable ilnd Ihe block should he fa"ly strong With J strong leuulm blue spark_ (Hold (he lead WI(h wbber to ilvold elec(IIc shocks) If Clluelll is reilching (he plugs. then rel110Ve them and clean and reg,lp them. Tho engine should now SWrt 5 If there is no spilrk ilt the plug leilds. wke of! the HT lead from the cenlre of the d'sltibutor C 6 If Ihere me no spmks Irom the end of the lend 110m the coil check the connections atlhe coil end of the lead. If il is in order 5(31 1 checking (he low tension circuit. 7 Use iI 12V voltmeler or a 12V bulb ilnd two leng(hs of w ire. On conventional distributors switch on the ignilion i1nd ensure tha t the points arc open. On breakerless dlstlibulOlS ensure thilt Ihe segments on the rOlor are nOt adJilcenl to (he triggel coil. Make a tes t between the low tension wire to the COil ( + ) terminal nnd eilrth. A leading of 7 (0 8 'lollS should be obtained. N o reJding indiCiites a break in the supply from the ignition swilCh or il f,1UIl in the ballast resiswnce wire. A correct rending indicn(es a faulty cojl or condensel, or n blok en lend between the coil ilnd the distrIbutor. On breokedess ignition systems the (rigger coil and ilmplificr module are suspect . H~ve (hem checked by a Ford dealer. . 8 Take the condenser wire off the points assembly Jnd with the points open test between the moving point ilnd eMth. If there is now a leildrng then the tault is in (he condenser. Fit a new one as dcsclibed in this Chapter, Section 5 9 W,th no reilding from the moving point to eilrth, wke ,1 reildrng between eil/th ,1nd the ell or negiltive ( - ) teminal ot (he COIl. A rendm(J here shows a broken wire which will need to be renewed hetween (he COil ilnd dis(rihutor. No retlding confirms thil1the coil hilS failed ilnd must be renewed, afler which the eno"te wdl run once more Rcmtmher (0 rel,t tho condenser wire 10 the pomt$ ilssemhly.
Engine misfires 10 If the enOlnr. mlsfues re!Julariy. run It ilt a f~st irllrng speed. Pull off eilch 01 the plu(! C,lpS III hUll nnd hsten t o (he note 01 the engrne. Hold the phl(J cnp In il dry cloth or with a rubber g love other Pollt of the dlstllhu(or. These lilles J,e p,lths which now conduct electllcit y Jcross the CJp lhus lewng it run to e,,'th. Tile only answer IS a new distllbutor CilP_ 16 APilit frorn the Ignition tll1l1ng being Incorrect. other Ciluses of rlllsl,,,ng hilve already been denl( w l(h under Ihe section dealrng with the f,lriUre of Ihe enuine to star I. To reCi!p - these 0110 Ih,lt:
(,J) The cOllm.lV be {,lufly giving ,111 iniNmil/elll mislile (b) Thele limy he ,1 (/iJmiJged wile or loose cOrlflee/ioll in till! low (eflsion circuil (c) The condensel /II,lY I;e shOll circuiling (i{ filled) (d) There nwy be a meehanic,lllolUI! IiI Ihe dis/flbll/or (bfOken dliving spindle or eOlllac/bleaker spring. if filled)
17 If the ignition (iming is too far reto1lded, it should be noted thallhe engine will tend to overheat. and there will he a quite no(iceable drop in powel. If the engine is overheating and Ihe power is down, and Ihe ,oni(ion tim in!) is correct. then Ihe carburenor or fuel injection should be checked, i1S ,I is likely that this is where the Iilult lies.
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Chapter 5
Contents
CIUICh il$scmhty '"SIJoCcl'Qn . Clu\(;11 assembly 'Urn!!ll!) Clutch llsscmhly lemOY," C lutc h cilhle .efluwal._
Clutch
Clutch !Jedal rClllovnl illld ,cflltl"U
Specifictions
Genera l Type ..... Clutch (lise (hamClcr lining tlnckncss Clutch pedal hcc " Torque wrench setting Pressure plate (Isscmhly
Gene.al description
,
5 3 1 8
All manu:!1 transmission madllis covered by this manual nrc lilted Wilh a singlo dl3phrilgll SpllJlg clutch. The unit COlllt)riscs il steel cover which is dowelled and bolted to the tear lace of the lIywheci ilnd conla i.lS the pressure plnte. diaphragm spring and fulCrum .ings . The clutc h " iClio n disc is
ee to slice along the splineJ gearllox
Inpu t Shillt and is held in posi t,on between the flywheel and the pressure plate by the pressure of the pressure plate spring , Friction linIng materiill is riveled 10 the d,sc and II has a spring cushioned hull to absorb transmission shocks and to help ensure a smoo th take oft. The circular diaphrilUm spring is mounted on shoulder pins ilnd
'Ield in place in the cover b.,. two fulcrum rings . The spring is also held ,0 th e pressure platc by three spling steel clips which are rive ted in
posi tion .
The
clu tC h ,s aCluated b.,. a cable controlled b.,. the clulCh pedal.
Clutch '0Ie,150 bCilfl"U -remova' and wl,u,"g Filult (ioilU"OS'S -clutch Generill descllptlon . noutlilc rn,untenanco .
SlIlgle (Iry plate. dlill)hragm sprong. cilhle ·ope.ated 241,3 rnm (95 Ill) 381 nun (0 15 In) 27.01 40mm (1.OG:i 0 .16,n)
No. Ib l It 16 to 20 12 10 15
G 9 1 2
The clutch release mechanism consists 01 a .elease leve. and a bearing which conwcts the lelease Imgers on the pressure plilte assembl.,.. The eHect of an.,. wear of the friction ma terial in the clutch is adjuSled out b.,. means 01 a cable adjuster at the lowel end 01 the cable where it
passes through the bell housing .
Dep.ess lng the clutch pedal actuates the clutch release leve. b.,. means of the cable . The lelease level pushes the lelease bearing
forward to bear against thO release l ingels so moving the centre of the diaphf()gm sprong within the annular rings which act as fulcrum points.
A s th e centrO of thO spring is pushed in. the outside of the Spling is pushed OUI. so Illoving Ihe pressure plme backward and disengaging the p.essu.e plate flom the /tielion disc . When the Clutch pedJI is Icleased. the diaptllaglll spring torces the plessule plate into contac t w ith the frictIon linings on the d,sc and at the saIne t,me pushes it a flactlon 01 an InCh fOlward on I\S splines . The
disc is now fuml.,. sandwic h ed between the plcsswe plnte Dnd the
flywheel. so the d.ive IS laken up.
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Chapter 5 Clutch
?
4 7
/ ,
Fig 5.1 Clutch components (Sec 1)
Ruutine 1\1,lintC!1aIlCC
I FrwllO" d,sc ? }"".HIlfL' II/"'e ilHL'wlJly J "''''I.·o'R' /II .'''''''fJ oml 1001, ./ 11"',.""se /,."w"
AI tl1" U(itHv;lls spec(hud ((1 lh" llolll((1(J M ,((ntcnanCI! SeCI(OIlIll Ihe 111 of 11((1 Inilnu;!l. callY (Jut Ihe follow,,,\) pI<)c"dUlu
5 C"Ma 6 CI(I((:/' /1I:d,d 7 Rllsh 8 SI>tJlly dil'
CII/teh pUdo1l and c,1hle adjustment 1 Apply the handlH,lke til(:" J'lck lip the h01l1 ulthe Cill iII ld support 011 ilxle sl,lnds 2 Ensure thilt the c illtd, c;Jble 'S not klilked. Ihell pull the nllwr cilbt e 10lWilid hum the ch,tch houslI1g to lake up the f rec pl,lY Release the locknut ,1ud lurn the a(illlstln9 Ilut ~o thilt 11 IS an,lulst thc "i>utl1lenl f,Ke of the clutch houslnU (photo) 3 Fu lly dcp,e~s Ihe clutch pedill seve'ill ulnes 10 en~u'e correct seat ln\! of Ihe cable components. then check thilt the hOI! t(< F ig . 5.2 Clutch p edal fr ee travel adjustment (Soc 2 )
A .. 270t40mm(106± O/6J1l)
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Chapter 5 Clutch 99
--.;,:;.~.--.
. '
3 I V,,'W 01 Ihe clutch wIth the Ue,IIbox r~movcd
1 If IH,<:~SS;lIy. ill'" Ihe sOllie cady modcis ;lIe lIot lilted wlih a lock"ut 5 Lower the C 3 Clutch .. ssembly -remov .. 1
I Remove the ~Jenrbox .. 5 described in Chapter G (photo). 2 Ma,k Ihe chltd, cove, e,"""'! idcnll<:nl positionin\] illhe cumponelllS .. re Ie· used 3 l"O'lre~slvcly ullSCWW Ihn clulCh (".ove, holts then Wllhdr"w Ihe a,,~,,",I!ly homlhe dowels on Ihe lIywhnol ~nd Illn h,,;I IOI1 pl;lIC IInecossary. hold Ihe lIywlwel siailonary hy 10d",U
II", ~1'''I'·r ""!I Uoar (photo).
1 Cili lch assemhly -inspectioll
Ex;"nIlIO IllI] 1", :lio n dISC lor we,ll ollhe In<:lIon 1ll'lIe"al. for bwkell .j ,;pllilUS. (ilSlull rOll of the rilll "ml we;lr all the splmos Unless the
. 1I:h plate IS In ve'y \Jood condlliull II is ;I false "cono"'y not 10 hi J
II""" ono ? The I"ctron d,sc should he ren ewed as as "ssemhly II IS adviscd Ih.ll th,s co\m;r~ IS prelelahle to lIymB 10 1'1 .. IIew I"ctlon IIIHIlU· :3 Chec k tho tnJchlned Iilces 01 Ihe flywheel "nd p'essure plate . lithe Ilywheells scoled. II should he relllove<1 "lid m~ch",cd Illhe preSSIJle pl.lIe IS scored. cluic h nnd II si9nS 01 le"ks "re found. rec t,ly Ihe le"ks be/Ole hlling Ihe
clutch.
5 E x nmlllC Ihe diapl""9fll sprinu lor wear ,lIld <1 be f illed 6 Check Ihe release bearinu for smoothness 01 opcration.11 should be re~son"bly hee. benring in mind Ilwt II IS pre ·p"cked WIth grease "nd Ihele should nOI be ;lny roughness. or slac kness. in il.
., Ch eck Ihe comt.tion ollhe dolCh spigol be .. ring in Ihe end 01 Ihe o""kshillt. Further inlorlllillion on this is given in Ch;lpICr 1.
5 Clu tc h assembly _ relitting
Note: A chI/eli CCII(r,l/ising roo/ is required in (his See (ion. I IllS IInpOllanllhal no od or gre.lse gelS onlO th(l friction mated,,1 01 h,c t,on diSC 01 on 10 the laces of Ihe lIywheel find pressure plalc. It ,~advisi,llle to have clean hands when rel'lIing the dolCh and 10 w ipe lho lIywheel ;lIld pressure [lla\\! surfaces wilh clean rag belore
I~assernhly IS s1 I
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33 One method 01 10cklllH the Slarter lin!) \lo"r wlHle \II1SCleWll1U
the clulCh cover hailS
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Fig . 5.3 Clulc h centr" lising nHllldrel dimellsio ns ISec 5 )
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1626 111111 (061 ill) 25101ll11! (100 1ft) 3175 mill (125 1ft)
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rI .• 44.15 mm (I 75 ill) IIImil!l(IfII (: ~ 15210111111 (6.00 ill)
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5.2 Friction disc FLYWHEEL SIDE marking
2 The friClion disc is Il,arkcd flvwlwcl shit· (photo) and il i$ impol1anl Ihal th is face . which can 11150 be idenl,lled by ils haVing the longe, cenllal boss. ;s plnced againSI Ihe lIywheel. The cushion springs and reJaining pl"te muSI b(l ollsel away hom lhe Ilywheei. 3 Loca te the Inctlon disc "nd cover "ssembly on t he lIywheel with the cover cOlleclly positioned on J he loc .. ting dowels (phOto) . If lhe oliginal assembly is being , efllled .. lIgn Ihe previously made marks .
<1 Insell Ihe reta,ning boilS I"'ger Ilghl.
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