1. MW-Motorrad
emoving rightside panel
i
KU.SI RAGOOSb
• Open stowage-compartment lid (1).
• Remove the following components, noting the retainers(arrows):
- Screws(2)
- Screws(3)
- Screws(4)
- Side panel(5)
^/20^0

2. MW-Motorrad
emoving rightside panei
• Open stowage-compartment lid (1).
• Remove the following components, noting the retainers(arrows):
- Screws(2)
- Screws(3)
- Screws(4)
- Side panel(5)
?/2010

3. MW-Motorrad
emoving clutch slave cylinder
KU R21C«a>
A Attention
Ifthe clutch lever is pulled v^/ith the slave cylinder or the clutch cover removed,the
is a possibility ofthe piston dropping out ofthe slave cylinder or suffering damage.
Do not operate the clutch lever with the slave cylinder or the clutch cover removed
Remove screws(1).
Pull clutch slave cylinder(2)outofthe clutch cover and lay it aside in such a way
that there is no strain on the line.
E/2010

4. MW-Motorrad
emoving clutch cover
RaA_3J ftnai36
^Removing heatshield from crankcase cover,right
• Remove the following components:
- Screws(1)
- Heatshield(2)
K44Jt.Rt10l4&
• Remove the following components:
- Screws(1)and(2)
- Clutch cover(3)
- Thrust piece(4)
- Thrust bearing(5)
- Seal(6)
>/2010

5. MW-Motorrad
]21 21 000 Removing and Installing or replacing clutch
•- 21 21 606
K44 (KSOtGfl
Preparatory work
Removing right side panel
Removing complete engine spoiler
Removing clutch slave cylinder
Removing clutch cover
Core activity
(-) Removing clutch cage
^Removing crankshaftsensor
• Remove screw(1).
Attention
Oil is hazardous to the environment; oil can attack plastic and rubber parts; oil
spillages make the ground slippery and dangerous.
Catch escaping oil.
• Pull out crankshaft sensor(2)and allow it to danglefrom the cable,taking care n
to lose or damage sealing ring(3).
» Note that oil can escape from the bore in the crankcase.
^Locking engine with locating pin
• Introduce locating pin {No, 11 1 842)into the sensor bore.
• Install screw(1)to secure the locating pin.
» Engine locked.
Remove nut(1)from the clutch while holding the clutch cage with driver lock(No
21 4651).
^/20^0

6. MW-Motorrad
21 4651_;^
K53HV_R2lOlCb
MW_R210066
^Removing plate cluster
• Remove plate cluster(1)and thrust washer(2).
11 1 842
—
MA mi021&
^Removing locating pin
• Remove screw(1).
• Remove locating pin(No. 11 1 842)from the sensor bore.
Preload tensioning gear(1)ofthe alternatorfreewheel with locating pin (No. 11 2
671).
fir
Note
Do not remove or install the locating pin unless the clutch cage is installed.
- Insert the locating pin vertically asfar as it will go.
- Turn the locating pin to the horizontal position.
5/2010

7. MW-Motorrad
-7
M3HV^ft2100Sn
• Remove clutch cage(2).
(+)Installing clutch
(+)Securing crankshaft sensor
Finishing work
Securing clutch cover
Securing clutch slave cylinder
Installing entire engine spoiler
Installing right side panel
Final check of work performed
2/2010

8. MW-Motorrad
]21 21 000 Removing and installing or replacing clutch
H 21 21 606
Preparatory work
Removing right side panel
Removing complete engine spoiler
Removing clutch slave cylinder
Removing clutch cover
Core activity
(-) Removing clutch cage
^Removing crankshaftsensor
• Remove screv*/(1).
A Attention
Oil is hazardous to the environment; oil can attack plastic and rubber parts; oil
spillages make the ground slippery and dangerous.
Catch escaping oil.
• Pull out crankshaft sensor(2)and allow it to danglefrom the cable,taking care n'
to lose or damage sealing ring (3).
» Note that oil can escape from the bore in the crankcase.
1 842
^Locking engine with locating pin
• Introduce locating pin(No. 11 1 842)into the sensor bore.
• Install screw(1)to secure the locating pin.
» Engine locked.
Remove nut(1)from the clutch while holding the clutch cage with driver lock(No
21 4651).
?/2010

9. MW-Motorrad
214651 /r .'
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K43HV RJtoioe
tesiiCTii
M3HVIQini»>
^Removing plate cluster
• Remove plate cluster(1)and thrust washer(2).
K44.R1102t6
^Removing locating pin
• Remove screw (1).
• Remove locating pin(No. 11 1 842)from the sensor bore.
Preload tensioning gear(1)ofthe alternatorfreewheel with locating pin(No. 11 2
671).
Note
Do not remove or install the locating pin unless the clutch cage is installed.
- Insert the locating pin vertically asfar as it will go.
- Turn the locating pin to the horizontal position.
>/2010

10. MW-Motorrad
y^KiSHvjnioo®
Remove clutch cage(2).
(-)Installing clutch
Adjusting chain tension of oil-pump drive
> Removing bearing for oil-pump drive
• Remove sleeve(1)and needle roller bearing (2),
<]
Slacken screw(1).
Insert eccentric gauge(No. 11 1 931)between the sprocketand the gearbox inpi
shaft.
Align the mark on the eccentric(arrow)at right angles to the oil-pump drive chain
Use your hand to push the tensioning rail toward the chain and tighten screw(1).
NTightening torques
Chain guide,oil pump to crankcase
^/2010

11. MW-Motorrad
/
M2HV_ftnoi0b
111 931
K40Jll1CSa3
M6x20 10 Nm
!VI6x30 lONm
• Without applying more pressure againstthe tensioning rail, turn the sprockets twi
full turns counter-clockwise.
• Align the mark on the eccentric(arrow)at right angles to the oil pump drive chain
Test
• Check the tension ofchain(1).
m
Result:Chain too tight or too loose
Measure:
• Repeatthe adjustment procedure.
• Remove eccentric gauge(No. 11 1 931).
> Installing bearing for oil-pump drive
• Lubricate needle roller bearing(2)with engine oil.
• Install sleeve(1)and needle roller bearing(2).
<
Slide clutch cage(2)onto the gearbox shaft.
>/2010

12. MW-Motorrad
K13HV.RJI0050
K43W R21000l>
• Preload tensioning gear(1)with locating pin(No. 11 2671
» The locating pin is horizontal.
• Push clutch cage(2)onto the gearbox shaft until tensioning gear(1)engages
tensioning gear for alternatorfreewheel(4)and crankshaft pinion (5).
• Install assembly tool(No. 21 4652)in clutch cage(2).
» The drilled hole in the assembly tool is above the mark(arrow)on clutch cage(2)
• Turn clutch cage(2)counter-clockwise with assembly tool(No.21 4652)until
gearwheel(3)engages.
• Push on clutch cage(2) until seated.
» The gearwheels ofclutch cage(2)and crankshaft(5)are flush atthe outside.
A Attention
If the oil-pump drive is unable to transmit sufficient driving force, an adequate
supply of lubricant to the engine is not ensured.
Make sure thatthe oil-pump drive is reliably able to transmitsufficient driving force
to the pump.
• Pull the oil-pump drive chain(arrow)to check thatthe oil-pump drive is correctly
engaged in the rear ofthe clutch cage.
» Hold the clutch cage and check that the oil-pump drive chain no longer moves
freely.
Remove locating pin(No. 11 2671)from tensioning gear(1).
2/2010

13. MW-Motorrad
K43MV_R21008c
K43»<V.R2IOl«n
K43HV R210)1
^Installing plate cluster
Lubricating new plate cluster
A Attention
Clutch plates can burn if Installed dry.
Immerse the new clutch-plate stack In clean engine oil before installing.
• Before slackening cluster(1), apply a mark(arrow).
- Do notchange the positions ofthe lined plates relative to each other.
• Slacken screws(2)until the clutch plates can be turned.
• Immerse plate cluster(1)in engine oil.
» The friction faces ofthe lined plates are wetted by oil.
• Turn the lined plates to the positions Indicated by the mark(arrow).
Align the lettering(arrow)ofthe first plate projection with the bore(arrow)in t
clutch cage.
Note
There is only one position in which the plate cluster can be fitted into the clutch cag
Install spacing washer(1)and plate cluster(2). noting the mark applied when the
plate cluster was lubricated.
In order to insert plate cluster(2),engage a gear and turn the rear wheel by hanc
Tighten screws(1).
Tightening torques
Pressure bowl to pressure plate
M5x 16 tighten In diagonally
/2010

14. MW-Motorrad
KAiHV ft2lOl7b
opposite sequence
8^^ Nm
M4.Rno?1b
^Locking engine with locating pin
• Introduce locating pin(No. 11 1 842)into the sensor bore.
• Install screw(1)to secure the locating pin,
» Engine locked.
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214651 i£. ,
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Install nut(1), while holding the clutch cage with driver lock(No.21 4661).
Tightening torques
Clutch to gearbox inputshaft
M20X1.5 190 Nm
^Removing locating pin
• Remove screw(1).
• Remove locating pin(No. 11 1 842)from the sensor bore.
/2010

15. MW-Motorrad
M4_Rn02t
(+)Securing crankshaft sensor
Finishing work
Securing clutch cover
Securing clutch slave cylinder
Installing entire engine spoiler
Installing right side panel
Final check of work performed
?/2010