Gilera Nordwest, Workshop Manual

Page: 64 / 136

DISASSEMBLY
Drain the oil.
Loosen the kick starter bolt; remove cover plate mounting screws and remove
right side cover of the engine block.
Remove the seeger ring and the thrust bearing (fig. 1).
Block the drive gear of the primary drive with special tool 19.1.20515.
Remove clutch assembly mounting screw and washer (fig. 2).
Remove clutch hub together with clutch plate, pressure plate and driving plate
(fig. 3).
Remove the gearbox mainshaft, washer, clutch drum and spacer (fig. 4).
Remove the kick starter shaft (fig. 5).
Loosen the balance shaft fastening bolt (fig. 6)
Remove mounting screw and spring washer and slide out the drive gear from
the crankshaft of the primary drive. Remove special tool 19.1.20515 (figs. 7-8-
9).
Remove the oil pump assembly complete with drive pinion (fig. 10).
Take off the pump’s rear cover and slide out the washer of the mainshaft.
Slide out both drive and driven gears from the balance shaft (fig. 11).
Remove the spacer washer near the right main bearing (fig. 9).
INSPECTION
After a thorough cleaning of all parts, inspect all components carefully. All
those parts that show sign of wear and/or damage must be replaced. All gears
must be in good condition, with no sign of wear, deep scratches or pitting.
Clutch
The drum notches must be perfectly straight. If there is pitting or undulations,
replace drum.
If the flexible coupling springs seat is worn, replace drum.
The clutch hub slot must have its sides perfectly straight. If there is pitting or
undulation, replace hub.
The metal driven plate must be perfectly plane. Check it with a surface plate.
Max. planning error = 0.1 mm.
Make sure the plates don’t show signs of overheating.
Measure the drive plate gap with a gauge (fig. 12).
Min. gap = 2.7 mm.
If one or more plates show sign of wear or deformation, all plates must be
replaced; it is recommended to replace the springs too.
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