Fig. 7.2. Measurement of a carving part of a tip of a cable of coupling: 1 – carving part of a tip of a cable of coupling; 2 – clip; 3 – the separating lever

1. Disconnect a wire from the negative plug of the rechargeable battery. Measure length of a carving part of a tip of a cable acting from the separating lever and write down value (see fig. 7.2).

Fig. 7.3. Elements of fastening of a cable of coupling to the separating lever: 1 – carving part of a tip of a cable of coupling; 2 – clip; 3 – nut

2. Remove a clip 1 (see fig. 7.3), turn off a nut 3 and disconnect a carving tip of a cable of coupling from the separating lever.

3. Lift the car and fix on support.

4. Remove an antisplash casing.

5. Remove the left forward wheel.

6. Remove the transmission.

7. Remove a lock ring from an end face of a main shaft of the transmission. Note the provision of a nave of the conducted clutch plate in relation to vents of a main shaft of the transmission.

8. Using KM-323 adaptation, turn out the screw from an end face of a main shaft of the transmission.

Fig. 7.1. Coupling elements: 1 – the separating lever; 2 – clip; 3 – nut; 4 – coupling cable; 5 – pro-masonry ring; 6 – washer; 7 – spring clamp; 8 – nut; 9 – washer; 10 – arm; 11 – axis; 12 – returnable spring; 13 – overlay of a pedal; 14 – coupling pedal; 15 – sealing ring; 16 – epiploon of a main shaft of the transmission; 17 – coupling cover; 18 – bolt; 19 – the directing basic plug; 20 – coupling switching off bearing; 21 – coupling switching off fork; 22 – plug; 23 – washer; 24 – bolt; 25 – the conducted clutch plate; 26 – press clutch plate; 27 – washer; 28 – bolt; 29 – bolt

9. Turn out bolts 18 (see fig. 7.1) and uncover the 18th couplings a forward part of a case of the transmission.

Fig. 7.6. Installation of a clip KM-526-A (1)

10. Take away the separating clutch lever back and install on press a drive one of three clips of KM-526-A 1 (fig. 7.6) for deduction in the compressed condition of a diaphragm spring.

Turn a flywheel on 120 ° and establish the second clip.

Turn a flywheel on 120 ° and establish the third clip.

       PREVENTION

Press the disk and the conducted clutch plate cannot be removed without the established clips.

11. Turn out bolts of fastening of a casing of coupling with a press disk.

12. Remove a casing of coupling with a press disk.

Fig. 7.7. Arrangement of a bolt (1) of fastening of a fork of switching off of coupling

13. Turn out a bolt 1 (see fig. 7.7) fastenings of a fork of switching off of coupling.

14. Extend the separating clutch lever 1 up (see fig. 7.1).

15. Remove a fork of switching off of coupling 21 and the bearing of switching off of coupling 20 from the directing basic coupling 19.

16. Turn out bolts of fastening of the directing basic coupling and remove the directing basic coupling.

Remove an epiploon of a main shaft 17 of the directing basic coupling 19.

Remove a sealing ring 18 of a case flute.

17. Remove the plug 22 (see fig. 7.1) a shaft of the separating lever.

1. Install the plug 22 (see fig. 7.1) a shaft of the separating lever. Grease with jellied lubricant working edges of an epiploon.

2. Install by KM-518 adaptation an epiploon of a main shaft 17 (see fig. 7.1) in the directing basic coupling.

3. Install the directing basic coupling 19 with a sealing ring 18 and fix by bolts, having tightened their moment 5 N • m. Grease the basic surface of the coupling with universal lubricant.

4. Grease the working surface of the bearing of switching off of coupling with the 20th universal lubricant.

5. Install the bearing of switching off of coupling 20 with a fork of switching off of coupling 21 on the directing basic coupling 19.

6. Install the separating lever in the top part of a case of the transmission as follows:

– establish a shaft guide through a fork of switching off of coupling 21;

– center a shaft in a coupling switching off fork, establish a washer 23 and screw a bolt 24, having tightened its moment 35 N • m.

7. Establish new press a disk 26 on a table of a press, press fingers and establish three press spring clips of KM-526-A around a press disk equally spaced.

8. Establish press a disk 26 and the conducted clutch plate 25 on a flywheel as follows:

– a long part of a nave of the conducted clutch plate has to be directed towards the transmission;

– grease vents on the conducted clutch plate a little;

– center press a disk on a flywheel;

– screw 2 bolts 28 with washers of the 27th fastening of a casing of coupling with a press disk and tighten their moment 15 N • m.

Fig. 7.8. Centering of the conducted clutch plate

– center vents of the conducted clutch plate with vents of a main shaft (fig. 7.8).

9. Screw the remained bolts 28 with washers of the 27th fastening of a casing of coupling with a press disk and tighten their moment 15 N • m.

10. Establish a main shaft.

11. Screw the screw in an end face of a main shaft and tighten its moment 15 N • m.

12. Establish a lock ring on an end face of a main shaft, at the same time the slanted edge of a ring has to be directed to a transmission case.

13. Install the transmission and tighten a stopper the moment of 50 N • m.

14. Remove three spring clips of KM-526-A.

15. Establish a cover of the 18th coupling on a forward part of a case of the transmission and fix by bolts, having tightened their moment 7 N • m.

Check oil level in the transmission for what turn out a stopper of check of level and be convinced that oil is at the lower level of the opened opening. If the level of oil is lower, add oil through a bulk opening until it does not begin to pour out from an opening for a stopper of check of level.

16. Establish an antisplash casing.

17. Establish a forward wheel.

18. Lower the car.

19. Install a coupling cable on the separating lever.

20. Screw a nut on a carving part of a tip of a cable of coupling on the same distance at which it was before removal.

21. Adjust a coupling cable.

22. Establish a clip 2.

23. Connect a wire to the negative plug of the rechargeable battery.

Bolts of the directing basic coupling........ 5 N • m

Bolts of fastening of a fork of switching off of coupling to a shaft of the separating lever......... 35 N • m

Bolts of fastening of a press disk to a flywheel......... 15 N • m

Screw of a main shaft........ 15 N • m

Case stopper......... 50 N • m

Coupling cover bolts......... 7 N • m

Coupling pedal course......... 142 ±4 mm