Large Frame Clutch Rebuild

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Large Frame Clutch Rebuild



	Torch Hammer (rubber and regular) Clutch Tool T-20322 Flat Head Screwdriver Chisel Pick Channel Locks Small Block of wood Vice (not nessasary)
	Insert the screw part of clutch tool into back of the clutch (side with the gear)
	Flip the clutch over and insert the ring part
	Put the nut part into the vice (if you are using one) if not just put the nut on
	Screw it into the nut
	You can tighten it simply by spinning the whole clutch clockwise
	Once it is full compressed use a small flat head screwdriver to pry off the Circlip
	Continue working it around
	Pull it off
	The top plate may be difficult to remove if so use a screwdriver to pry it off
	Once to top plate of off you can grab the gear and remove all the rest of the plates

	Inspect the cork plates REPLACE them Inspect the metal plates they should not be shiney if so REPLACE
	This is no goood they should not be black or burnt most likely if you are rebuilding the clutch these are the problem ALWAYS REPLACE
	Inspect the Drive Gear it should have no play whatsoever (hold the plate still and try to move the gear (it should be tight)
	If it is loose simply use a ball peen hammer and smash the rivets flat.
	Inspect the Brass Bushing if it is loose or scored in anyway REPLACE it. Next loosen the clutch for the tool by spinning it counter clockwise
	Pull the tool out
	Pull the Backplate off Six Spring 159905 Seven Spring P200 159853
	ALWAYS replace the Springs
	Remove the Brass Washer
	To remove the Bushing (if it doesn't just pull off with your fingers) Hit it with a chisel one swift hit should do it. Don't hit it too hard you don't want to damage the backplate.


	Remove the Springs
	Remove the Cups
	Inspect the Clutch Basket check for cracks REPLACE if necessary.
	Time for Reassembly
	Put the Heat on the Brass Bushing NOT TOO MUCH just hold the flame on for a few seconds don't discolor it.
	Use your channel locks to pick it up IT'S HOT!!
	Place it on the Back Plate Six Spring 159905 Seven Spring P200 159853
	Get the Brass Bushing started with the rubber end of you hammer
	If you have a vice place your block of wood on the bushing side and slowly close the vice.
	If you don't have a vice you can use the old bushing to hammer the new one on.
	Remember SLOWLY if you go to fast you can crack the bushing

	Put your Clutch Tool T-20322 nut back into the
	Put the basket on the ring part of the tool
	Replace the Cups
	Replace the Springs
	Replace the Back Plate Six Spring 159905 Seven Spring P200 159853 Make sure on the P200 you align the hole in the back plate with the hole in the basket
	Insert the Screw part of the tool
	Again spin the clutch clockwise to compress the Springs. Only compress them about half way
	Using a small pick of screwdriver push the tops of the Springs until they make a CLICK sound. THIS IS VERY IMPORTANT YOUR CLUTCH WON'T WORK PROPERLY IF YOU SKIP THIS STEP!!
	This is what you are doing (CLICKING the springs into the recesses on the Back Plate Six Spring 159905 Seven Spring P200 159853
	Compress the springs all the way now.
	Install the Brass Washer
	Oil the Brass Bushing with SAE30 oil
	Install the Drive Gear making sure it spins freely
	Install the OIL SOAKED cork plate
	Install the metal plate
	Another cork plate
	Another metal plate
	Finally the last cork plate will go on cork side down
	Install the circlip by holding it in place with you finger and working it into the groove with the other.
	When you are done the break in the Circlip should be on a solid part of the Basket
	There you have it, now that wasn't so bad was it