Note:
- Thoroughly clean all parts with solvent or carburetor cleaner and dry with compressed air.
- Purge all channels.
- Lubricate all components with transmission fluid before assembly.
1. Check check valve, if it is loose, replace piston.
2. Install new O-rings on the clutch piston.
3. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper fit.
Note: Do not over-compress the O-ring by pushing the piston in with excessive force.
4. Install the return spring and spring retainer and place the circlip on the retainer.
5. Install the special tool as shown in the illustration.
Note: Installing the special tool with either end on a section of the spring holder that is not supported by the back spring may damage the holder. Make sure that the special tool is in full contact with the spring holder.
6. Compress the return spring.
7. Install retaining ring.
8. Remove the special tool.
9. Install the Belleville spring in the direction shown.
10. Thoroughly soak clutch discs in recommended transmission fluid for at least 30 minutes.
11.Check that the inside of the clutch drum is clean and free of foreign matter.
12. Starting with the clutch plate, install the clutch plates and discs alternately. Place the coupling end cap with the flat side against the disc.
13. Put a lock ring.
14. Be convinced that a backlash in the lock of a lock ring correct.
15. Use a dial gauge to measure the clearance between the coupling end cap and the top disc. Set the indicator to zero by lowering the coupling end cap and lift it up to the retaining ring. The distance the clutch end cap moves is the gap between the clutch end cap and the top disc.
Note: Measure at least three locations and take the average as the actual gap.
Gap between coupling end cap and top disc: standard: 0.6-0.8 mm.
16. If the clearance is greater than allowed, select a new coupling end cap from the following table, then recheck.
Note: If the thickest coupling end cap is installed, but the clearance is still more than acceptable, replace the coupling discs and plates.
Forward Clutch End Cap
Cap No | catalog no | Thickness |
1 or 15 | 22561-P4V-003 | 3.5mm |
2 or 16 | 22562-P4V-003 | 3.6mm |
3 or 17 | 22563-P4V-003 | 3.7mm |
4 or 18 | 22564-P4V-003 | 3.8mm |
beat 19 | 22565-P4V-003 | 3.9mm |
6 or 20 | 22566-P4V-003 | 4.0 mm |
7 or 21 | 22567 P4V-003 | 4.1 mm |
8 or 22 | 22568-P4V-003 | 4.2mm |
9 or 23 | 22569-P4V-003 | 4.3 mm |
10 or 24 | 22570-P4V-003 | 4.4mm |
11 or 25 | 22571-P4V-003 | 4.5mm |
12 or 26 | 22572-P4V-003 | 4.6 mm |
13 or 27 | 22573-P4V-003 | 4.7mm |
17. After replacing the coupling end cap, check that the gap is within tolerance.