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Rebuild Tutorial:
Disassemble
- Introduction
- Bearing and Seal Replacement
- Disassemble
- Assemble
Suggested Operation - disassemble Tool
Description Sequence
Click for photos; use 'back'
button to return
Step 1 (image
1) Tool, size: standard
13mm socket.
remove (5) pressure plate nuts
remove springs & plates items
Step 2. Tool,
size: standard spanner &1/2" drive
breaker bar / 19mm socket.
hold & remove clutch hub nut
hold clutch hub
remove clutch hub
Step 3 (image
3) Tool, size: standard
5mm hex wrench, dead blow hammer.
remove (10) clutch cover screws
use small dead blow hammer or block of
wood to free up cover (ensure that clutch
release pushrods located in trans mainshaft
are secured until reassembly)
Step 4 (image4) Tool,
size: standard snap
ring pliers.
remove 20mm snap ring from crankshaft
slip off drive gear
Step 5 (image
5) Tools, sizes: standard
spanner & 1/2" drive breaker
bar & 20mm socket, rotor
puller
ihold & remove PVL rotor nut - part
of
Step 6 (image
6) Tool, size: rotor puller
remove PVL rotor
Step 7 (image
7) Tool, size: standard
4mm hex wrench
remove (3) stator plate screws
remove stator plate
Step 8 (image
8)Tools, size: standard
12mm box end - reduced box section
remove (4) cylinder nuts
remove hose, cylinder & gasket
Step 9 (image
9) Tool, size: standard/
standard 5mm socket
remove (17) crankcase screws
gently remove one crankcase half from
mating half
tap with wood block or small dead blow
hammer to loosen sealer
work cases from end to end to break shafts
loose from bearings - do not pry
remove crankshaft assembly
Important:
- The disassembly of the crankcase is necessary when preparing to replace crankcase bearings and seals or rebuild crankshaft.
- Separate sections will explain bearing, seal replacement
- keep all loose parts organized in clean container for reassembly