Complete Disassembly
1. Remove the primary chaincase cover. See 5.3 PRIMARY CHAINCASE COVER, Removal.
2. Remove clutch assembly. See 5.4 DRIVE COMPONENTS, Removal.
3. Follow all partial disassembly information under 5.6 CLUTCH: CONVENTIONAL, Clutch Pack Only.
Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a)
NOTE
Do not disassemble the clutch shell and hub assembly unless the bearing, hub or shell require replacement. Replace the bearing if disassembled.
Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a)
4. See Figure 5-32. Remove retaining ring.
5. See Figure 5-33. Support clutch shell in arbor press with ring gear side up. Use a suitable press plug to press hub from bearing in clutch shell.
6. See Figure 5-34. Remove retaining ring from groove in clutch shell bore.
7. See Figure 5-35. Support clutch shell in arbor press with ring gear side is down. Use a suitable press plug to remove bearing.
8. Clean and inspect components. See 5.6 CLUTCH: CONVENTIONAL, Clutch Pack Only.
Assembly
1. Place clutch shell in arbor press with ring gear side up. Support clutch shell bore on sprocket side to avoid damage to ears on clutch basket.
2. Using a suitable press plug, press against outer race until bearing contacts shoulder in clutch shell bore.
Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a)
3. See Figure 5-34. Install retaining ring with flat side toward bearing.
4. Place clutch shell in arbor press with sprocket side up. Center hub in bearing. Support bearing inner race with a sleeve on transmission side.
5. Press hub into bearing until shoulder contacts bearing inner race.
6. See Figure 5-32. Turn assembly over. Install retaining ring in groove of clutch hub.
7. Assemble clutch components. See 5.6 CLUTCH: CONVENTIONAL, Clutch Pack Only.
8. Install clutch. See 5.4 DRIVE COMPONENTS, Installation.
NOTE
Always install a new gasket between primary chaincase cover and chaincase. Failure to replace this gasket may cause primary chaincase leaks.
9. Install primary chaincase cover. Fill primary chaincase with lubricant. See 5.3 PRIMARY CHAINCASE COVER, Installation.
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