Front Reduction Driven Gear: Assembly

Check the clutch clearance.

Place the surface plate on a weight scale, and place the dish plate, driven plate, drive plate and retaining plate on the surface plate.
Set the magnet stand and dial gauge to the surface table, and contact the dial gauge on the retaining plate to adjust the reading to the zero point.

Adjust the reading of the weight scale to the zero point, place a weight so that the reading value of the weight scale becomes 13.3 kg (29.4 lb), and then measure the compression amount "A.

NOTE:

Prepare a weight with the length of one side equal to or longer than the retaining plate diameter, and also flat shape that allows load to be applied evenly.
Measure at four points at 90° intervals and calculate the average.

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(A)	Retaining plate
(B)	Driven plate
(C)	Drive plate
(D)	Dish plate

Install the dish plate, driven plate, drive plate, retaining plate and snap ring.

NOTE: Face the painted surface of dish plate toward the driven plate side.

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(A)	Snap ring
(B)	Retaining plate
(C)	Drive plate
(D)	Driven plate
(E)	Dish plate
(F)	Front reduction driven gear

Measure the clearance "C1" between snap ring and retaining plate using a thickness gauge.

NOTE: Before measuring, press down the whole circumference of retaining plate using your finger to fit in.

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(A)	Snap ring
(B)	Retaining plate

Using the following calculation, calculate the clutch clearance "C.

Service limit:

3.36 mm (0.133 in)

C = A + C1

C	Clutch clearance (mm (in))
A	Measured value (mm (in)) of (3)
C1	Measured value (mm (in)) of (5)

If the value exceeds the limit, perform the following operations.
1. Measure thickness of the retaining plate.
2. Replace the drive plate and driven plate with new parts, and then perform measurement from step 1 again.
  Initial standard:
  
  2.4 - 2.8 mm (0.09 - 0.11 in)
3. If it exceeds the initial standard value, adjust the thickness of retaining plate to be within the initial standard value.

Using a press, press-fit a new ball bearing.
NOTE: Apply CVTF to the press-fitting area.

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Install a new seal ring.
NOTE:
- Apply CVTF to the seal rings.
- Do not stretch the seal ring more than necessary.
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Install the front reduction driven shaft.

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(A)	Front reduction driven shaft
(B)	Front reduction driven gear

Install the front reduction driven gear.

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Blow compressed air through the hole shown in the figure, and check the piston operation of the front reduction driven gear.
NOTE: Hold the hole (a) area with a cloth.

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