Hi all,

I am about to perform the 4K service myself (plus oil/filter/final drive oil change). After looking at the service manual, it appears that I cannot inspect the thickness of the clutch shoes on my own (without buying a lot more tools to tear it all apart).

Does anyone know how quickly these shoes wear out? The service manual says to inspect every 4K miles but never says when to replace them. Is it worth paying Honda to just do this part of the 4K service? Or does anyone know of an easier way to inspect them (other than taking the whole clutch apart)? Or should they be fine at 4K miles?

Has anyone had them replaced and if so, at what mileage?

Thanks!

--Russ

Hi Russ,

Remember...Tools are the best investment and the next is having the smarts on how to use them.

Have you inspected your drive belt before? If you have a Harbor Freight tools around your home, head on over and pick up a set of large metric impact sockets, and some other smaller metric sockets, I suggest you use only 6 sided sockets on the scooter.

You will also need a set metric "T" handel Hex Key set.

This is the set I got from them and they work GREAT! Only $4.99 at this time. They look cheep but they work good.
http://www.harborfreight.com/10-piece-color-coded-t-handle-metric-hex-key-set-37862.html

If you need help...Just ask.

Yeah, I have a great set of tools, including those. However, the tools to disassemble the clutch are specific and not likely to be used for anything else (hence my hesitation to buy them).

--Russ

Russ,

Just trying to help.

If just looking at the clutch pads to see if within spec., all you need is a 22mm impack to remove the driven assembly, that's it....Just 1 nut and a re-torque to 40 ft.lbs. when you reassemble. Do you have a digital caliper?

Unfortunately, I do not have a caliper nor an impack? Is that like a 22mm socket wrench?

-Russ

Hi Russ,

http://www.harborfreight.com/hand-tools/sockets-accessories/8-piece-3-8-eighth-inch-metric-deep-wall-impact-socket-set-3655.html

Or a set of these with a 1/2" to 3/8" adapter.

http://www.harborfreight.com/hand-tools/sockets-accessories/13-piece-1-2-half-inch-metric-deep-wall-impact-socket-set-34683.html

All with 6 sided hex so you won't strip out the bolt or nut heads.

From what I can tell, impact sockets need an impact (air-powered) wrench. I don't have that nor the money to invest in one right now.

Would it be possible to undo this nut with a regular socket wrench? This picture in the service manual seems to allude to that, but they use a "universal holder" tool to keep the clutch from rotating as it would otherwise turn with the nut.

Has anyone solved this issue without having to buy a "universal holder"?

--Russ

That's an awesome tool and sure beats the $91 price tag honda wants for the universal holder. However, I'm looking for something to hold the clutch still (as opposed to the drive pulley).

And is that nut that keeps the clutch on indeed 22mm? Or is it 12mm? Can someone verify? The service manual doesn't specify.

Thanks!

--Russ

Hi Russ,

OK...Using a 6 point (6 sided) socket, ether impact or standard socket will lessen your chances, considerably, of stripping the hex head off the oil drain plug on your scooter. The darn thing is made of aluminum!

Thanks Dennis, but I'm not talking about the oil drain plug, but rather the nut to take off the clutch. What size is it?

As an aside, I saw in another post that the oil drain plug is 24mm size. But I can't find that in 6-point (just 12). Does it come in 6 point? Or is there a non-metric equivalent?

--Russ

22mm (Like I mensioned to you earlier) and impact sockets are 6 points (always). They are just like standard sockets and come in 3/8", 1/2", 3/4" and 1" drives.

P.s. This is my last entry on this topic. good luck!

Thanks for the tips! I really appreciate it. I'm going to try it out this weekend. It looks (according to the service manual) that as long as I don't disassemble anything other than just taking off the clutch, there are no parts to replace (like seals) or parts to grease. That's a relief. Now, to find a 1/2" 22mm 6-point deep socket somewhere local....

As for the oil drain nut, I got a 15/16" 1/2" drive socket and it seems to fit just fine (as no one carries a 24mm 6 point socket here locally). We'll find out this weekend if it works!

--Russ

Last question (well at least for now....). Does anyone know if I actually need a deep 22mm socket? Or will a regular one work just fine?

--Russ

Thanks! What is that the variator and do I need to remove it to or just the clutch in order to check the shoes? The manual does not show any of the parts being called a variator...

--Russ

Oops...Who knew? Honda refers to it at the Drive Pulley.

See page 10-6 of the Manual. Universally a variable drive pulley assembly like this is called a Variator.

So here's some of my own tips after successful completion:

1) I used a 6 point deep socket 22mm for a 3/8" drive on the clutch nut. Worked like a charm using just the parking brake. I had to step on the wrench handle to break it free. Clutch shoes had about 5mm thickness at 4K miles.

2) Used a 6 point standard 17mm 1/2" drive socket for the drive pulley (had to take off the face to get the belt off to get the clutch off). Made the nifty board contraption here which also worked like a charm. Used a 3/8" driver wrench with a 3/8 - 1/2 adaptor. Also had to step on the wrench to break the nut free.

3) Be careful that if you move forward the back of the drive pulley any, the back half may separate and all the rollers may all out - yikes!

4) When reassembling the drive pully, you won't be able to get the face fully back on as you can't move the belt back into position with only two hands (I tried all sorts of tricks). However, torquing it to 76 ft-lbs will certainly get the job done.

Cheers!

--Russ