Vespa GTS Super 300 ie - Service manual > Removing the clutch

Fit the driven pulley spring compressor specific tool with medium length pins screwed in position "C" on the tool internal side.

• Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
• Fit the driven pulley unit on the tool with the insertion of the 3 pins in the ventilation holes in the mass holder support.
• Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to loosen/tighten the clutch nut.
• Use the special 46x55 wrench component 9 to remove the nut fixing the clutch in place.
• Dismantle the driven pulley components (Clutch and spring with its plastic holder)

CAUTION

THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CONTACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE.

Specific tooling
  020444Y011 adapter ring
  020444Y009 wrench 46 x 55
  020444Y Tool for fitting/ removing the driven pulley clutch

Inspecting the clutch

• Check the thickness of the clutch mass friction material.
• The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.

N.B.

UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.

VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

CAUTION

DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Check minimum thickness
1 mm

Pin retaining collar

• Simultaneously turn and pull the collar manually to remove it.

N.B.

USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICULTY.

N.B.

BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.

• Remove the 4 torque server pins and pull the pulley halves apart.

Removing the driven half-pulley bearing

• Check there are no signs of wear and/or noisiness;
• Replace with a new one if there are.
• Remove the retainer ring using two flat blade screwdrivers.
• Support the pulley bushing adequately from the threaded side using a wooden surface.
• Using a hammer and pin, knock the ball bearing out as shown in the figure.

• Support the pulley properly using the bell as shown in the figure.

Specific tooling
  001467Y035 Bearing housing, outside ø 47 mm

• Remove the roller bearing using the modular punch.

Specific tooling
  020376Y Adaptor handle
  020456Y Ø 24-mm adaptor
  020363Y 20-mm guide

Inspecting the driven fixed half-pulley

• Measure the outside diameter of the pulley bushing.
• Check the faying surface with the belt to make sure there are no flaws.
• Check the riveted joints are functional.
• Check evenness of the belt contact surface.

Characteristic

Half-pulley minimum diameter
Minimum admissible diameter: Ø 40.96 mm
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Wear limit
0.3 mm

Inspecting the driven sliding half-pulley

• Remove the two seal rings and the two O-rings.
• Measure the movable half-pulley bushing inside diameter.
• Check the faying surface with the belt to make sure there are no flaws.
• Check the riveted joints are functional.
• Check the evenness of the belt contact surface.

MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Refitting the driven half-pulley bearing

• Support the pulley bushing adequately from the threaded side using a wooden surface.
• Fit a new roller bearing as shown in the figure.
• For the fitting of the new ball bearing, follow the example in the figure using a modular punch.

  Fit the retainer ring

WARNING

N.B.

FIT THE BALL BEARING WITH THE VISIBLE SHIELDING

Specific tooling
  020376Y Adaptor handle
  020375Y 28 x 30 mm adaptor
  020424Y Driven pulley roller casing fitting punch

Refitting the driven pulley

• Insert the new oil seals and O-rings on the movable half-pulley.
• Lightly grease the O-rings "A" shown in the figure.
• Fit the half-pulley over the bushing using the specific tool.
• Check that the pins are not worn and proceed to refitting them in their slots.
• Refit the torque server closure collar.
• Using a curved-spout grease gun, lubricate the driven pulley unit with approximately 6 grams of grease. Apply grease through one of the holes in the bushing until it comes out through the hole on the opposite side. This operation is necessary to avoid the presence of grease beyond the O-rings.

N.B.

THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING REPLACED; UNDERTAKING THE OPERATION WHEN THE BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

Specific tooling
  020263Y Driven pulley assembly sheath

Recommended products

AGIP GREASE SM 2 Gray black smooth-textured lithium grease, containing molybdenum disulphide.

See also: