[jakedog]

Hi -

I removed the right crankcase cover to replace my primary drive clutch. I tried using an impact wrench to get the nut off, but the metal was extremely brittle and it just stripped out. I had to drill a hole in nut and use a chisel and hammer to get it off. The outer tabs of the friction plates were really burnt. I'm guessing the heat caused the nut to become brittle?

In looking at reassembly (after I get new clutch nuts and oil seals), anyone have any suggestions on how to keep the clutch cam plate, spring, and clutch lifter plate in place when I put the cover back on?

 

[Helmut]

Hi -

I removed the right crankcase cover to replace my primary drive clutch. I tried using an impact wrench to get the nut off, but the metal was extremely brittle and it just stripped out. I had to drill a hole in nut and use a chisel and hammer to get it off. The outer tabs of the friction plates were really burnt. I'm guessing the heat caused the nut to become brittle?

In looking at reassembly (after I get new clutch nuts and oil seals), anyone have any suggestions on how to keep the clutch cam plate, spring, and clutch lifter plate in place when I put the cover back on?

Are you talking about these parts?



If you are, then just place them like they are in the diagram below. I always turn the 4-wheeler all the way over on it's side, so that the parts will be laying flat and level. That way they will stay better, without falling off. Just be careful and not shake the engine much when you put the clutch cover back on and they should stay. They always stay for me, anyway.

 

[Helmut]

Don't forget to line the punch mark on the clutch lever up with the mark on the case as in the picture below. Also, don't forget to put the bearing back in the center of the lifter plate as in the second picture.

 

[jakedog]

What exactly do the loose pieces do? Are they used for reverse?

Thanks

 

[Helmut]

What exactly do the loose pieces do? Are they used for reverse?

Thanks

The loose pieces that lay on top of the clutch is what disengages and engages your clutch when you shift gears. The gear shifter shaft actuates them. That clutch lever fits over the end of the shift shaft and when you shift gears it moves those pieces and they disengage and engage your clutch. There's a piece on the inside of the clutch cover that sits down on top of those pieces and you can see the adjusting bolt on the outside of the clutch cover where you adjust the clutch free-play, but if you haven't messed with that adjustment, then you want have to adjust it. It will still be adjusted right.

Those pieces don't have anything to do with reverse, but the piece below is the reverse lock out or stopper shaft. The second picture shows the reverse lockout shaft in position. This shaft keeps it from going into reverse until you push the red button and pull back on the lever to put it in reverse, then the lever on the end of the shaft turns the shaft around allowing you to push down on the shifter and then it will go from neutral on down into reverse.