DISASSEMBLY AND REASSEMBLY



Disassembly steps
<<A>>
 >>E<<
 1.
 Lock nut
<<B>>
 >>D<<
 2.
 Ball bearing


3.
 Oil guide


4.
 Sprocket spacer


5.
 Steel ball


6.
 Drive sprocket


7.
 Needle bearing


8.
 Sprocket sleeve


9.
 Steel ball

>>C<<
 10.
 Clutch sleeve
<<C>>
 >>B<<
 11.
 Clutch hub
<<C>>
 >>A<<
 12.
 Stopper plate
<<C>>
 >>A<<
 13.
 Ball bearing


14.
 Rear output shaft

DISASSEMBLY SERVICE POINTS

<<A>> LOCK NUT REMOVAL

1.Remove the lock nut from the shaft.

2.Hold the drive sprocket in a soft-jaw vice.
3.Shift the clutch sleeve to the drive sprocket side.
4.Use special tool Power steering lock nut special spanner (MB991013) to remove the lock nut.

<<B>> BALL BEARING REMOVAL

1.Use special tool Bearing remover (MD998801) to support the ball bearing.
2.Use a press to push at a rear end of the rear output shaft, and then remove the radial ball bearing.
note
    The bearing may fit loosely on the shaft, so that removal is possible without using a press.

<<C>> CLUTCH HUB / STOPPER PLATE / BALL BEARING REMOVAL

1.Place special tool Bearing remover (MD998801) so that the load is applied at the bearing.
2.Use a press to push at the rear end of the rear output shaft, and then remove the clutch hub and ball bearing.
note
    The clutch hub may fit loosely on the shaft, so that removal is possible without using a press.

REASSEMBLY SERVICE POINTS

>>A<< BALL BEARING / STOPPER PLATE INSTALLATION

1.Fit the ball bearing and stopper plate onto the rear output shaft.
2.Use special tools to press in the ball bearing.

  • Bearing remover (MD998801)
  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer-200 (MD998814)
  • Installer adapter (60) (MD998829)

>>B<< CLUTCH HUB INSTALLATION

1.Confirm the clutch hub installation direction, and fit onto the rear output shaft.
2.Use special tools press in the clutch hub.

  • Bearing remover (MD998801)
  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer-200 (MD998814)
  • Installer adapter (44) (MD998821)
note
    The clutch hub may fit loosely on the shaft, so that installation is possible without using a press.

>>C<< CLUTCH SLEEVE INSTALLTION

Check that the clutch sleeve is in the correct direction for installation.

>>D<< BALL BEARING INSTALLATION

Use special tools to install the radial ball bearing.

  • Bearing remover (MD998801)
  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (44) (MD998821)
note
    The ball bearing may be fitted loosely on the shaft, so that installation is possible without using a press

>>E<< LOCK NUT INSTALLTION

1.Hold the drive sprocket in a soft-jaws vice.
2.Shift the clutch sleeve to the drive sprocket side.
3.Using special tool Power steering lock nut special spanner (MB991013) tighten the lock nut to the specified torque of 255 ± 10 N·m.

4.Stake the two places of the lock nut as shown in illustration.