6.3 -
Clutch assembly: primary drive gears
1
Clutch drum/Primary drive gears
2
Spacer
3
Threaded ring nut
4
Lock washer
Spare parts catalogue
1200 ABS
Clutch
1200 ABS
connecting rods
1200 S ABS
Clutch
1200 S ABS
connecting rods
Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but
which can be found in the exploded view diagram.
Removal of the primary drive gear
Operation
Section reference
Drain the engine oil
4 - 3,
Changing the engine oil and filter cartridge
Remove the undersump assembly
5 - 4,
Removing the undersump
Remove the clutch cover
9 - 6.2,
Removal of the clutch-side crankcase cover
Remove the clutch assembly
9 - 6.1,
Removal of the clutch
Withdraw the clutch housing (1) complete with driven gear of the primary pair (A).
Remove the inner spacer (2).
Remove the oil pump (C) (Sec.
9 - 2.1,
Removal of the oil pump
).
Lock the primary pinion (B) with the holding tool
88713.3417
and loosen the threaded ring nut (3) using the bush part no.
88713.3406
.
Remove the nut (3) and safety washer (4).
Remove the complete primary drive gear (B) using a commercial puller and placing a brass or aluminium pad between the end of
the crankshaft and the puller screw.
Remove the spacer (D).
Refitting the primary drive gears and checking backlash
Fully degrease the crankshaft splined end and the corresponding spline on the primary drive gear.
Position the spacer (D) onto the crankshaft.
Fit the driving gear (B) onto the crankshaft with the oil pump drive sprocket facing the crankcase.
Temporarily secure the gear with the washer (4) and nut (3).
Important
If fitting a new primary driving gear (B), check the backlash.
To check the clearance, temporarily fit the clutch bell (
1
) complete with the primary driven gear (
A
) on the gearbox primary shaft. Fix a dial gauge to the engine crankcase, positioning the stylus against a gear tooth.
Turn the driven gear (
A
) to mesh the teeth and check that clearance ranges between
0.05
and
0.07
mm.
Repeat the check at 16
different points of the driven gear.
If the measured values are outside the permissible tolerance limits, try changing the position of driven gear (
A
) on the primary shaft, leaving the driving gear (B) on the crankshaft. If the clearance is still outside the tolerance limits, replace the primary drive gear pair (
1
).
After checking backlash, fit the bush
88713.3406
on a torque wrench, lock the pinion (B) with the holding tool
88713.3417
.
Position the washer (4) and the ring nut (3). Use the special tool (U), to tighten the ring nut (3) to a torque of 190 Nm (Min. 171
Nm - Max. 209 Nm) (Sect. 3 - 3,
Engine torque settings
).
Refit the oil pump (C) and check the clearance between the oil pump gear and primary drive gear on the crankshaft (Sect.
9 - 2.1,
Refitting the oil pump
).
Thoroughly degrease the mating surfaces of the clutch bell (
1
).
Fit the spacer (2) onto the primary shaft. Fit the clutch housing (1) along with the driven gear (A).
Operation
Section reference
Refit the complete clutch assembly
9 - 6.1,
Reassembling the clutch
Refit the clutch cover
9 - 6.2,
Refitting the clutch-side crankcase cover
Refit the undersump assembly
5 - 4,
Refitting the undersump
Refill the engine with oil
4 - 3,
Changing the engine oil and filter cartridge
1