Forward Clutch

DISASSEMBLY OF FORWARD CLUTCH




1. REMOVE THRUST BEARINGS AND RACES FROM BOTH SIDES OF CLUTCH
Note the position of the races.




2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE, DISCS AND PLATES




4. COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING
a. Place SST on the spring retainer and compress the springs with a shop press.
SST 09350-32013 (09351-32070)

b. Remove the snap ring with snap ring pliers.

5. REMOVE SPRING RETAINER AND THE EIGHTEEN SPRINGS




6. BLOW OUT PISTON
Apply compressed air into the oil passage to remove the piston.
If the piston does not come out, use needle-nose pliers to remove it.


INSPECTION OF FORWARD CLUTCH



1. INSPECT CLUTCH PISTON
a. Check that the check ball is free by shaking the piston.
b. Check that valve does not leak by applying low- pressure compressed air.




2. INSPECT DISC, PLATE AND FLANGE
Check that the sliding surfaces of disc is worn or burnt. If the disc is worn or burnt, replace all discs.
Then check that the sliding surfaces of plate and flange are not worn or burnt.
If necessary', replace them.

NOTE: Do not allow the discs to dry out.

Prepare new discs by soaking them at least two hours in ATF.




3. REPLACE OIL SEAL RINGS
a. Remove the oil seal rings.
b. Spread the rings apart and install them into the groove.

CAUTION: Do not spread the ring ends more than necessary.


ASSEMBLY OF FORWARD CLUTCH



1. INSTALL NEW O-rings ON PISTON
Coat the O-ring with ATF.

2. INSTALL PISTON IN FORWARD CLUTCH DRUM
Press the piston into the drum with the cup side up, being careful not to damage the O-ring.




3. INSTALL THE EIGHTEEN PISTON RETURN SPRINGS, SPRING RETAINER AND SNAP RING IN PLACE

4. COMPRESS RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE
a. Place SST on the spring retainer, and compress the springs with a shop press.
SST 09350-32013 (09351-32070)
b. Install the snap ring by hand. Be sure the end gap of snap ring is not aligned with the spring retainer claw.




5. INSTALL PLATES, DISCS AND FLANGE
Install in order:
Plate-disc-plate-disc-plate-disc-plate-disc
Then install the flange facing the flat end downward.

6. INSTALL OUTER SNAP RING
Check that the end gap of snap ring is not aligned with one of the cutouts.

7. CHECK PISTON STROKE OF FORWARD CLUTCH






If replacing the disc, plate or flange, check the piston stroke.
Using a dial indicator (long type pick or SST), measure the forward clutch piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.
SST 09350-32013 (09351-32190)

Piston stroke: 1.11 - 1.47 mm (0.0437 - 0.0579 in.)

If the piston stroke is less than the limit, parts may be misassembled and reinstall them.
If the piston stroke nonstandard, select another flange.

NOTE: There are two different flange thickness.
Flange thickness:
- 2.60 mm (0.1024 in.)
- 3.00 mm (0.1181 in.)

8. INSTALL BEARINGS AND RACES