Clutch Housing Disassembly

Clutch Housing Disassembly









1. Remove the Crank Lever Shaft (8mm Hex / Allen)




2. Remove the 5th Reverse Counter Lever




3. Remove the Front Bearing Cover
- Remove the bolts (seven - 12mm)
- Pry off the cover with a pry-bar through the shift fork hole




4. Remove the Oil Seal from the front cover using a seal remover




5. Remove the 2-front Snap-Rings from the Main Drive Gear Bearing and from the Countershaft Bearing
- Discard the Snap-Rings, they must be replaced with new ones




- You may need to encourage the shafts to leave the housing. Support the transmission shafts at the back of the housing and use a 2x4" piece of wood and a soft faced hammer

Combine Step 6 thru 10




6. Remove the Mainshaft
7. Remove the Countershaft
8. Remove the Shift Fork and Rod Assembly
9. Remove the Reverse Idler Shaft
10. Remove the Reverse Gear

Optional, Combine Step 11 thru 15

Steps to disassemble the Reverse Idler Gear






Optional Step




11. Remove the Snap-Ring

Optional Step




12. Remove the Spacer

Optional Step




13. Remove the Friction Gear

Optional Step




14. Remove the Torsion Spring
15. The Reverse Idler Gear is bear




16. The Clutch Housing is bare
Inspect the Reverse Gear for Radial Clearance







- Use a vice with jaw protectors and
- a dial indicator
- Write down any parts that need replacement on the Repair Order