Note: If the release bearing drive sleeve is removed, a new O-ring must be used for installation.
Removing
1. The release bearing can be accessed either by removing the clutch assembly as described in chapter 5 (engine and transmission in the engine compartment), or by separating the engine from the transmission (clutch assembly stays in place).
2. Unscrew the clamp bolt that secures the clutch release fork to the pivot pin of the release lever.
3. If not already done, disconnect the clutch cable from the release lever by removing the clip from the tip's threaded rod and pulling the rod out of the lever.
4. Remove the release bearing from the guide sleeve, then remove the release lever pivot pin from the clutch housing and remove the clutch release fork (see illustrations). If applicable, remove the bearing from the plastic ring.
5. Make sure the release bearing rotates smoothly.
While holding the outer ring of the bearing, try to move its inner ring in a horizontal plane.
If the bearing rotates unevenly or its rings are significantly displaced relative to each other, replace it.
The release bearing must also be replaced if a new clutch is installed.
6. If required, remove the release bearing guide sleeve by unscrewing the three mounting bolts. After that, the input shaft seal can be replaced. Remove the O-ring installed between the guide sleeve and the clutch housing. Remove the old oil seal from the guide bushing using a screwdriver as a lever, and install a new oil seal using a tubular punch or socket. Fill the space between the packing lips with lithium grease, then install the guide bushing using a new O-ring. O-ring must be installed without lubrication (see illustrations).
7. If necessary, replace the plastic bushings supporting the release lever pivot pin by knocking them out of the clutch housing with a punch. Insert the new bushings into place, making sure that their locking tabs fit into the corresponding grooves in the clutch housing (see illustration).
Installation
8. Installation of the release bearing and lever is carried out in reverse order, paying attention to the following.
9. Lightly coat the inner surface of the release lever pivot bushings and the outer surface of the release bearing guide bushing with molybdenum grease.
10. Where applicable, install the release bearing in the plastic ring, then install the release bearing with the release fork and tighten the release clamp bolt to specification (see illustration).
11. Install the clutch assembly as described in chapter 5 or reconnect the engine and transmission as described in Sections 2A, 2B or 7A (depending on the model).
12. Finally, check the clutch cable adjustment as described in Chapter 3.
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