Removing the Clutch

With the rear hub and wheel removed, you now have access to the clutch. To make it easier to get to the clutch, remove the bottom bolt of the rear shock from the motor. This will allow the motor to swing down a bit more. For even more access, remove the carburetor and the carburetor air box at the top of the motor.

With the motor down, you can see the clutch cover, which is often referred to as the "clutch bell" due to its rounded shape. It is held on by three bolts. Remove the bolts, and pull off the cover.

You may need to use a screwdriver as a lever on the clutch actuating arm to break the seal and get the cover off. Do not lever between the cover and the case.

Swing the clutch cover down and away from the motor. If you are careful, you will not have to replace the clutch cable. If your clutch cable is in poor condition, clip the cable and remove the clutch cover.

To gain access to the clutch nut, first, remove the clutch push pad. The pad is held in place by a spring clip. Note that there are two holes on the push pad. With a screwdriver, push the clip towards the center of the push pad from the wide hole and the pad will come free from the clutch.

The clutch is held in place by a special castle nut. The nut is locked by a locking tab on a special tab washer which is peened over onto the nut. Find the tab which is folded over the nut, and using a small screwdriver, push the tab flush against the side of the clutch.

Two special tools are required to remove the clutch. The castle nut remover (top picture) is essential, I would not attempt to remove the clutch without this tool. The second tool is a clutch holding tool (bottom picture). The holding tool locks the clutch in place so while removing the nut. Though the clutch can be removed without the holding tool using a screwdriver to lock the clutch risks damage to the clutch or motor case. Luckily, both of these tools are cheap, and are available from any reputable scooter shop.

Use the holding tool to lock the clutch while you remove the clutch nut. This nut can be very difficult to remove. An air impact wrench makes quick work of it. If you don't have access to an impact wrench, you can use a long ratchet, or a breaker bar to ease the nut off the crankshaft.

Use two flat head screwdrivers as a lever to slide the clutch off the crankshaft. Put even pressure on the back side of the clutch with the screwdrivers. The clutch can be stuck on, so sometimes a rocking motion with the screwdrivers can help free it.

If you have a scooter with oil injection, the clutch woodruff key will be held in place by the drive gear on the crankshaft. Remove the oil drive gear from the crankshaft and then remove the woodruff key from the crankshaft. If the scooter is a non-injected model, just remove the woodruff key. If it is damaged, get a replacement for it, but do not install it on the crankshaft yet.

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