Necessary equipment
- J-28585 Retaining Ring Remover
- J-45186 Forward and Direct Clutch Spring Remover
- J-25024-A Clutch Spring / Booster Piston Puller
- J-23327 Clutch Spring Remover
1. Remove the O-ring, thrust bearing and cage.
- Remove the O-ring from the input shaft assembly.
- Remove thrust bearing and race.
2. Remove the flange, disc and plate of the forward clutch (C1).
- Using J-28585, remove the circlip.
- Remove 1 flange, 4 discs and 4 plates.
3. Remove the flange, disc, plate and flexible disc of the direct clutch (C2).
- Using J-28585, remove the circlip.
- Remove 1 flange, 4 discs, 4 plates and 1 elastic disc.
4. Remove return spring assembly.
- Place J-25024-A in a vise with the pressure bolt at the bottom and back.
- Install J-45186 onto the direct/forward clutch housing shaft and input shaft assembly.
- Place J-21420-2 from J-23327 on top of J-24024-A push bolt.
- Compress the clutch spring with a pressure bolt so that the retaining ring can be removed.
- Using J-28585 or circlip pliers, remove the circlip.
- Remove tools.
- Remove return spring assembly.
Attention! Protective goggles should be worn when working with compressed air to prevent injury to the eyes.
5. Remove direct clutch piston (C2).
- Install the input shaft assembly to the rear crankcase.
By pressing the piston by hand, apply compressed air (4 kg/cm?) into the lubrication channel as shown in the figure and remove piston C2.
Important: Be careful not to damage the o-rings in the rear crankcase.
- Remove O-ring from piston C2.
Attention! Protective goggles should be worn when working with compressed air to prevent injury to the eyes.
6. Remove the forward clutch piston (C1).
- By pressing piston C1 by hand, apply compressed air (4 kg/cm?) into the lubrication channel as shown in the figure and remove piston C1.
- Remove the O-ring from piston C1.