CLUTCH & GEAR ASSEMBLY
engine Breakdown
PART 2
In the second part of this four-part tutorial, you will learn how to disassemble the clutch basket and gear assembly on the Benelli moped engine. Visit the “Manuals” section of my website for the parts catalogues with exploded diagrams of the engine and transmission.
01
Drain
oil
Drain the clutch oil before removing the engine pannel. Unscrew bolt (A) then (B) and drain the clutch oil into a container.
02
engine
panel
The righthand engine panel is removed by unbolting three 40 mm, two 46 mm and two 35 mm socket cap Allen Key bolts using a 5 mm (H5) Allen Key.
03
Preselector
body
The preselector body assembly is easily removed by unclipping the spring and lifting the whole assembly free of the engine casing.
04
centre
nut
Carefully remove the 24mm centre nut holding the clutch gear in place; the spring behind a 55mm diameter washer puts the nut under pressure.
05
Driving
Gear
A 17 mm hexagonal nut fastens the driving gear in place. Ensure the piston is locked before attempting to remove it.
06
Clutch Plate
holder
Turn the engine block on its side and slide out the clutch plate holder releasing the clutch plates. Now remove the key from the output shaft.
07
Clutch
gear
Remove the circlip from the output shaft and the washer behind it. The clutch gear will now slide off the output shaft.
08
Casing
bolts
The righthand side of the engine has two 76 mm socket cap Allen Key bolts directly above the output shaft.
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