Removal
1. Removing the clutch cover.
a) Turn the ignition switch to the "ON" position. Turn the clutch lock switch to the "OFF" position to release (FREE) the freewheel clutches.
b) Using a special key, unscrew the six cover mounting bolts.
c) Insert a flat-blade screwdriver between the coupling housing fastening nut and the cover, and remove the cover.
Attention:
- Move the coupling cover evenly one at a time, applying equal force at four points.
- Do not damage or scratch the coupling cover.
- To avoid deformation, do not use a hammer or similar tool when removing the coupling cover.
d) Remove the gasket from the clutch cover.
2. Removing the coupling housing.
a) Remove the retaining ring from the coupling housing.
b) Unscrew the four nuts securing the coupling housing and remove the washers.
c) Using a brass rod and hammer, remove the conical washers from the coupling housing mounting bolts.
Caution: Do not damage the coupling housing when removing the conical washers.
d) Remove the coupling housing together with the gasket.
Caution: Do not damage the brush when removing the housing.
3. Using a special key, unscrew the three mounting screws and remove the contact ring.
Examination
1. Checking the coupling housing,
a) Measure the height of the brush.
Standard height:
- A - 6.5 mm
- B - 4.7 mm
Minimum allowable height:
- A - 4.2 mm
- B - 4.2 mm
b) If the brush height is less than the minimum allowable, replace the clutch housing.
Attention:
- Do not remove the brush from the holder.
- Do not damage the brush spring.
2. Checking the coupling assembly.
a) Check for conductivity between the brush and the clutch housing.
b) If there is conductivity, replace the coupling housing.
Installation
1. Clean the bolts and bolt holes with solvent.
2. Installing the contact ring.
a) Clean the contact ring, lock nut, drive shaft and steering knuckle axle.
b) Align the projection of the contact ring with the recess of the steering knuckle axle and install the ring on the lock nut.
c) Make sure that the ring contacts are pressed tightly against the steering knuckle axis.
Caution: Make sure there is no oil or grease at the contact points.
d) Using a special key, install the three screws securing the contact ring.
Tightening torque: 7.4 Nm
3. After cleaning the contact ring again, apply a thin layer of Grease evenly around the circumference of the contact ring.
Lubrication: Part # 08867-02007, Castle Body Grease IV.
Caution: Do not apply any lubricant to the contact ring other than Castle YM102 No.2.
Note:
- Apply approximately 2-3 grams of lubricant.
- If no lubricant has been applied or a lubricant other than that specified above has been applied, there may be a lack of conductivity at low temperatures or premature wear of parts.
4. Apply a thin layer of lubricant evenly to the contact surfaces (sliding) body parts and clutch cover. Grease: Part # 08887-02007, Castle Body Grease IV.
5. Installing the coupling housing.
a) Align the dowel pins on the hub with the triangular notches in the new gasket and install the gasket.
b) Using wire, fix the brush as shown in the picture.
Caution: Do not apply oil or grease to the brush.
c) Make sure the brush is held in the holder.
d) Install the clutch housing onto the wheel hub. Install the cone washers and washers, tighten the mounting nuts.
Tightening torque - 31 Nm
Note: Before installing the clutch housing, make sure the brush is fixed.
d) Remove the wire from the coupling body.
6. Installing the retaining ring.
a) Screw the bolt into the axle shaft and pull it out.
b) Install the snap ring, then remove the bolt from the axle shaft.
7. Installing the coupling cover.
a) While holding the driven gear, turn the clutch hub counterclockwise to set the mechanism to the "FREE" position (unlocked)
b) Remove the protective film from the new gasket and install the gasket on the coupling cover.
Attention:
- Install the gasket with the adhesive surface (which had a film on it) to the coupling cover.
- Make sure there are no uneven areas and that the gasket is properly aligned.
c) Install the coupling cover onto the housing, aligning the pin on the cover with the hole in the housing, as shown in the figure.
d) Align the teeth of the driven and driving gears and install the clutch cover.
Caution: Make sure that the cover does not move relative to the body when pressing on it with your hand.
Note: If there is a gap between the cover and the clutch housing when tightening the cover mounting bolts, the locking mechanism parts may be damaged. If a gap is found between the cover and the housing, follow steps (a) - (d) and check for the absence of a gap.
d) Apply sealant to the threads of the coupling cover mounting bolts.
Sealant: Part # 08833-00080, Tree Bond 1344, Loctite 242 or equivalent.
e) Using the special wrench, tighten the six clutch cover mounting bolts.
Attention:
tighten in two passes:
- Tighten the bolts diagonally to a torque of 20 Nm.
- Tighten the bolts diagonally to 31 Nm.
8. Check the operation of the clutch.