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Refurbishing A Diablo Clutch

The engine flywheel was in very bad shape (see figure 1, 2) and was sent to Clutchmasters for repairs/replacement etc.  As can be seen below in figures 3 and 4, they did an outstanding job.

Flywheel  Clutch plate 
Fig 1. Flywheel exposed. Fig 2. Clutch plate
 
Fig 3. Flywheel and clutch reconditioned   Fig 4. Flywheel and clutch reconditioned
Madlyhs wanted to change the two seals in the clutch bell housing.  One was in the shaft support.  To remove that piece he had to remove the clutch lever in order to turn the fork upward to take it out.  The other seal is mounted on the gear housing where the differential shaft connects to the gear box. Both seals are relatively easy to change so it did not take much time.
 
Fig 5.   Fig 6.
 
Fig 7.   Fig 8.
Madlyhs noticed that when pushing the bearing on the fork towards the gear shaft sometimes the fork would hit the bell housing jamming it, and thus not allowing the fork to go all the way back.  This could contributed to clutch plate wear and tear as the clutch would not disengaging completely.  He decided to shave a bit from the housing were the fork hits the housing(fig 9, see arrow).  Moreover, he had the machine shop also make an aluminum plug which he plugged in thrugh the other opening on the gear housing. By doing so, the shaft to which the fork is mounted on is now probably aligned so that the fork will move forward and backward freely.
 
Fig 9. Cut away part of bell housing.   Fig 10.
He then mounted the clutch and pressure plate. He installed all the bolts for the pressure plate but none were tightened.
This was done so that he could mount the gear box to make sure that the gear shaft will slide in thus aligning the clutch correctly. After that he completely bolted in the gear box and then tighten all the bolts for the clutch plate thrugh the back opening on the gear housing. With that the gear box job was then complete.
Fig 11.   Fig 12.
     

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

This page was last modified on 03/12/2014

This page was last modified on 09/06/2014