Tip:
Highlight text to annotate it
X
Hi, today it's clutch day,
I will explain the clutch of the Largeframe models
so we're going to remove one from this engine
So I am going to start with that right now.
and then completely disassemble it.
The clutch cover is fixed with three screws,
which we have to loosen of course.
Once I remove the clutch cover
you will see a seal which is mounted here,
the so-called o-ring seal
I remove the cover and here comes the o-ring seal.
and here is the push rod
which you should always check for possible wear
You can tell the wear if it is worn-out on the bottom here
And here's already the clutch, what do we see here?
This is a Cosa clutch
You can tell that by the shape of the basket,
and also by the 1, 2, 3, 4, 5, 6, 7, 8 rivets,
on the inside of these rivets you can find 8 little springs.
Of course you will now have to loosen the spring here
so that you can remove this little disc
which is activated by the push rod
This is what the disc and the spring look like
and now I can see how the clutch is fixed
by a so-called lock nut
this is typical for a Cosa clutch
you can loosen this nut
but if you try to loosen it the usual way,
it wouldn't work as everything would rotate simultaneously.
So what do I have to do? I use the clutch holder tool
which looks like that
and mount it here.
In order to mount it here, I obviously have to
tighten the screw again and tighten it good enough
so that I won't damage the cast as there are several forces at work now
We can mount the holder as we have a couple of grooves here
If we rotate now that now a little,
then sooner or later it will hook in
Now I take a ratchet with a 19mm spanner socket
and we open up the whole thing
the nut is out
Once the nut has been removed,
please change it as it is a so-called lock nut
which locks tightly by being squeezed.
We remove the holder tool
but we can leave the screw in place
Now I can remove the clutch but please be careful when doing so
because you can easily loose the woodruff key, the clutch-side key
is usually seated here but before I take out the key,
I will show you a part which can be found just below the nut
This is the locking washer which should also be changed
Down here there is the woodruff key
As mentioned before, please be careful here
Clutch removed
I'd say we now go ahead and completely disassemble the clutch
for which I will first of all need an empty work space
I have cleared up that mess a little,
so that we can disassemble the clutch together
We start with a Cosa clutch which was the one mounted here
There is a tool which I find quite useful for this purpose
This is a clutch compressor
it compresses the clutch, i.e. the springs inside the clutch
so that the clutch releases its load
It works like this
You put the disc on here
and then hold it tight with your finger
enter here
and tighten the nut at the rear
All of this can still be done manually
Now take a 19mm wrench
and keep turning and turning and turning
Now the clutch load is completely released
This way you can now start to disassemble the clutch
The clutch is secured by a spring
which you can see up here, there is a ring
that's where I'll go in now
and now I can start removing the clutch plates
here you can already see the cork plates,
which in this case are a little worn-out
these plates should definitely be changed
and here comes the clutch gear
Clutch gears exist in different versions
Basically it has either 20, 21, 22 or 23 teeth
which influences your transmission ratio
Next comes a bushing
which will be removed
and checked for possible wear
If there is any clearance, it is worn-out
If it fits tightly, there is no wear
Then there is also the washer
which looks like this
We now remove the tool
which we tightened at the beginning in order to release the load
As mentioned, this is a Cosa clutch with 8 springs
1,2,3,4,5,6,7,8
You can buy these springs in different strengths according to your needs
You might want to check if any of these springs is broken or missing
or whether all springs are the same
You can easily exchange them by pulling them out here
Finally, we have completely disassembled the clutch
Now let's disassemble the PX old clutch
which is the other clutch that there is
It has a larger spring baseplate
You can also use the clutch compressor with this clutch
in order to release the load
It works the same way than with the Cosa clutch, it compresses here
so that I can remove the ring easily
Here are the clutch plates one after one
Just like with the Cosa clutch
I have a bushing on the inside
If it is worn-out, rattles and can be removed easily
then just exchange it for a new one
and here we go
Only this disc at the bottom is left now
so now we disengage our tool again
and you will see
that the springs start coming out
The springs are seated in these clutch plates
This is what the clutch basket itself looks like from a PX old clutch
If you have a tuned engine, I recommend using a Cosa clutch
because it can bear more load,
and is softer to engage
And then there is a clutch made by SIP
which is a sport clutch based on the Cosa version
I recommend using this clutch if you have engines with 15-20 hp
It features a ring welded to the clutch basket
Very good workmanship, ready to mount
For all the performance junkies among you
which have engines beyond 20 hp
I definitely recommend the CNC machined Race SIP clutch basket
which looks like this
This basket should definitely bear such loads
There is a reinforced spring you can mount
but you will have to bear in mind
that you won't be able to use the original clutch cover,
because this clutch just has too much height
You will therefore either have to mill out your clutch cover
or buy the already milled-out SIP clutch cover
It is based on an original cover
awsome thing as it fits plug&play
Alright, that's it, that's all
We're done for today
Here's some homework for you:
Open up your clutches,
if the plates are worn-out,
please change them and remember to bathe in oil overnight
very important!
Other than that you might just check what sort of clutch you have and whether it engages and disengages properly
is the clutch properly adjusted to your engine
If you have any questions, feel free to contact our SIP hotline
or look up the item codes in our catalogue, you can find the links down here
Have fun tinkering with your Vespa!