NOVARACING TRANSMISSIONS LTD MANUFACTURERS OF 6 PINNCALE CLOSE, PHOENIX LANE TRANSMISSION SYSTEMS CROWLAND, LINCS, PE6 OGB.UK. FOR RACING AND Company Reg: 2438157 Cardiff DEVELOPMENT VAT NO. 550-6594-34 Registered in England No 2438157 Tel: 01733 210082 Fax: 01733 211191 Email: info@novaracing.co.uk www.novaracing.com

Fitting Guide for Nova Suzuki RG500 Gamma Dry Clutch

Must be fitted in conjunction with the Nova Gearbox or Nova Dry Clutch Input Shaft (03978), as a longer shaft is required.

This guide gives a step by step guide to fitting the Nova Suzuki RG500 Gamma Dry Clutch Kit

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Contents Page Contents Page Number 1. Parts Included In the Nova Dry Sump kit 3 2. Fitting the crank primary gear 4 3. Fitting the clutch primary gear 5 4. Fitting the outer cover and clutch basket 6 5. Fitting the clutch hub and plates 7 6. Fitting the pressure plate 8 7. Fitting the outer cover 9 8. Finished Nova Suzuki RG500 Gamma Dry Clutch 10

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1. Parts Included In the Nova Dry Sump Kit

QTY Part Description Part no 1 Suzuki RG500 Clutch Back Plate 03895 1 Suzuki RG500 Cable Bracket 03897 1 Oil Seal 55 x 68 x 6 90194 1 Oil Seal 20 x 27 x 5 90321 1 Suzuki RG500 Pinion Retaining Screw 07012 2 Suzuki RG500 Cover Dowel 04018 1 Suzuki RG500 Outer Cover 03896 1 Suzuki RG500 Lever Support Bush 03958 6 M6 x 25 Stainless Cap Head 90035 8 M6 x 20 Stainless Cap Head 90022 1 Suzuki RG500 Clutch Basket 01512B 1 Nova Clutch Basket Driving Plate 02868 1 BRG 6205 2RS 90198 2 BRG Needle 30 x 37 x 16 90199 2 INA Inner Ring 25 x 30 x 17 90306 1 O Ring 52 x 2 90202 1 Nova Clutch Drum Inner Plate 02869 6 Nova Clutch Rivet 02870 6 Nova Cush Drive Rubber TZ500 Type 90195 1 Suzuki RG500 Clutch Hub 02825 1 Nova Clutch Hub Back Plate 02227 6 Nova Spring Pillar 02230 6 M8 x 16 Countersunk 90049 1 Suzuki RG500 Clutch Pressure Plate 02828 1 Suzuki RG500 Clutch Puller 03957 1 Circlip EXT 15 x 1 90124 1 BRG 6002 2RS Stainless Steel 15x32x9 90290 6 Dowel 8 x 20 90170 1 Suzuki RG500 Front Cover Plug 03083 6 Nova Spring Cup 02863 6 Nova Clutch Spring Washer 02231 6 Yamaha TZ350 Type Clutch Spring 90138 6 M6 x 20 Stainless Cap Head 90022 6 Yamaha Friction Plate 3mm Brown 90148 6 Yamaha Steel Clutch Plate 90154 1 Suzuki RG500 Dry Clutch Primary Gear 02339 1 Suzuki RG500 Coupling Primary Gear 06027 1 Honda Plain Washer 20 x 31 x 0.9 90107 2 Nova Clutch 3mm Spacer 02862 1 Nova Clutch Bearing Spacer 02865 1 O Ring 22 x 1.8 90212 1 Clutch Nut M20 x 1 03898

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IMPORTANT - Before installing the clutch ensure you have either installed the Nova Close Ratio 6 Speed Gearbox or transferred your

standard gears onto a Nova Dry Clutch Input Shaft (03978). 2. Fitting Nova Coupling Shaft Primary Gear This requires the bush pressing out of the old coupling shaft primary gear and inserting into the new gear. Using your original input shaft to push through the splines to remove the bush. Pressing back in is the reverse. Once the bush is pressed into the nova primary gear it can be re-fitted in its original location and bolted back in place. Tightening this gear properly can only be done once the clutch primary gear is in place so the two can be locked together.

A. Picture showing the fitted Nova coupling shaft primary gear.

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3. Fitting the Clutch Primary Gear

A. The clutch basket assembly will be supplied with all the required parts to fit as shown above.

B. The components shown above should be placed on the shaft in the following order:

3mm Spacer, BRG Needle 30x37x16, BRG INA Inner Ring 25x30x30, Clutch Bearing Spacer, BRG Needle 30x37x16, BRG INA Inner Ring 25x30x30.

C. Once on the shaft the components should line up as shown above.

D. Next slide the clutch primary gear over the bearings on the shaft and then slide another 3mm spacer up to the face of the primary gear. At this point fit the 22 x 1.8 ‘O’ Ring into the groove on the end of the shaft. If you have not yet done so at this point, you should tighten the coupling shaft primary gear.

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4. Fitting the outer cover and clutch basket

A. Replace the original gasket and the two cover dowels and fit the clutch cover using the supplied M6 x 20 cap screws.

B. The clutch basket will be pre-assembled with the back plate riveted in place and a 52 x 2.5 ‘O’ Ring and a BRG 6205 2RS Bearing pressed in the centre. Cush rubbers are pre-fitted behind the back plate.

C. Feed the clutch basket assembly onto the shaft. This can be a bit fiddly as the splined back of the basket will need to engage onto the spline of the clutch primary gear.

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5. Fitting the clutch hub and plates

A. The clutch hub is supplied with the spring pillars pressed in. Locate the clutch hub onto the shaft, sliding it onto the splines.

B. Locate the clutch retaining washer onto the end of the shaft and fit the supplied clutch nut. Ensure clutch centre nut is tightened fully.

C. Insert the clutch plates starting with a brown fibre friction plate (B) followed by a steel plate (S) and alternate until all brown plates are used up. The finished order from inside out should be: B-S-B-S-B-S-B-S-B-S-B-S.

D. The end of the shaft should be blanked off by some means. If your shaft is not blanked off, DO NOT CONTINUE the assembly. Oil will leak out of the shaft if this is not present. Please contact us if your shaft is not blanked off.

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6. Fitting the pressure plate

A. The pressure plate will come pre-assembled with 6 dowels and a 6002 2RS bearing. Also a clutch puller will be held in the center of the plate with a circlip.

B. Locate the pressure ensuring the dowels fit into the holes of the clutch hub.

C. Place one spring cup into each of the holes round the centre of the pressure plate followed by a spring, a retaining washer and secure in place by an M6 x 16 Screw.

D. Note: tighten down the screws in the sequence shown to ensure the pressure plate is seated properly. To make the next stage easier it is advisable to rotate the clutch puller so the rack is facing downwards. This makes it easier when trying to engage the pinion in the outer cover.

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24

3

56

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7. Fitting the outer cover

A. In order to fit the outer cover two cover dowels and three M6 x 30 cap screws are supplied. The original clutch actuation pinion (outlined above) will need to be retained.

B. Fit your original pinion into the new cover and secure in place with the supplied modified M5 x 10 cap screw.

C. Turn the pinion as the cover is fed on so it engages with the rack on the clutch puller. Insert the supplied top hat bush dowels through the case and clamp using the screws supplied.

D. If the cover plug is not already installed, fit into the centre hole in the cover. Secure with some locking compound.

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8. Finished Nova Suzuki RG500 Gamma Dry Clutch If you have any problems when fitting your dry clutch don’t hesitate to contact us on 01733 210082 or email us at info@novaracing.co.uk. For information on any other Nova products please check out our website at www.novaracing.com