See this staked nut??? You don't have to fool with it.



Clamp your new clamps exactly here, and remove one clip at a time. As you remove one rotate the clutch around and re-clamp and continue to remove until all of them are off. At this point you can remove the old springs and replace with the EPI setup. To reinstall the front plates you will re-clamp and install the C clips one at a time again, reverse of removal. Notice in my pic the purple EPI springs are already installed.


There's a reverse lock-out lever, and it will need to be positioned like this:


There's a shift lever that will need to be positioned like this: remember the mark on the case and the mark on the shaft will line up like on this pic:




For the kick-start the mark will need to face 12 o'clock. You will hook the spring up top, then spin the shaft around and lock the tang inplace in the bracket. Super simple.


Back to why my kickstart came off in my hands. Well apparently debris/paint/corrosion add up and cause an increase in shaft outside diameter and it doesn't want to come through the cover. To fix this before re-installation I buffed the shafts down. Here they are shined up and thinned down some. I did both the reverse shaft and the kickstart.




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This is a gasket prep disk, it removes just a touch of material. It's perfect for removing built up crud on the shafts. The grease we'll get to in just a second.



The grease you'll use to hold your triangle 3 ball bearing for your shift clutch as you re-install the engine cover. Spring goes out per the service manual.



And when its all done fill er up with this junk.

 

I needed this, thanks and nice write up. I got a little lost on where you put the welding clamps on at, I understand you have to take off the clips, and it think I know a way to do it, but im confused on your way, plus it sounds simpler than mine.
So does that make three people with a 300 clutch kit? You, trips, and ben613?

 

Sorry, confusion during posting and I missed a pic. I have added it now with the exact spot to clamp. Refresh the page and it should show. If not here it is:

 

cool thanks!! FYI you missed a pic elsewhere too, might just be the place you got the kit from, hint hint

 

Fixed it too.

 

The reason to clamp it here is because it is the only place the clamps will fit, as an FYI.

 

Nice write up man.

This should be stickied to the archive.

 

^^x2 this would help a lot of people to install a clutch kit.

 

Heck, I was having trouble with the reverse lock out shaft. My lever's D was 180 out from the shaft. Now I know why. Someone removed the cover and didnt install it correctly.My 88 Trx prob never had the reverse working for a long while. Thanks for posting the pictures! I may not have been needing a clutch but hey! Ya never know.
Now I know when I get home I'm taking the cover off, repositioning the reverse lockout shaft, cleaning the main oil screen and Viola! Re-assembly continues.

 

Glad it helped someone out. That's what we are here for right!