Tools Needed
- ½-inch drive ratchet
- 9/16-inch socket
- 7/8-inch socket
- ¾-inch socket
- 1-inch socket
- 5mm Allen wrench
Instructions
1. Remove the primary cover.
- Loosen the 9/16-inch bolts holding the primary cover to the engine case.
- Gently pry the primary cover off the engine case using a flat-head screwdriver.
2. Remove the starter clutch assembly.
- Using the 7/8-inch socket attached to a ratchet, loosen and remove the three bolts holding the starter clutch assembly to the engine case.
- Pull the starter clutch assembly straight out of the engine case.
3. Remove the old starter clutch.
- Remove the 5mm Allen bolt in the center of the clutch assembly
- Tap on the back of the clutch hub to dislodge it from the splined starter shaft
- Inspect the splines on the starter shaft and the clutch hub for wear or damage
4. Inspect the starter clutch assembly for wear or damage.
- Replace the starter clutch assembly if necessary.
5. Install the new starter clutch assembly.
- Apply a thin coat of high-temperature grease to the splines of the starter shaft and the clutch hub.
- Position the new starter clutch assembly onto the starter shaft and tap it into place with a hammer.
- Install the 5mm Allen bolt and tighten it to a torque of 10-12 foot-pounds.
- Install the three 7/8-inch bolts holding the starter clutch assembly to the engine case. Tighten the bolts to a torque of 20-25 foot-pounds.
6. Reinstall the primary cover.
- Place a new gasket between the primary cover and the engine case.
- Install the 9/16-inch bolts that hold the primary cover to the engine case. Tighten the bolts to a torque of 10-12 foot-pounds.
