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Removal
Remove the rear final gear case. See the Final Gear Case topic for more information.
There are two screws that hold the gasket to the swingarm.
Remove the two gasket screws with a Phillips screwdriver.
Remove the old gasket and discard it.
The wet brake clutch pack has four steel discs and threes friction discs. Remove the rear steel disc with the holes.
Remove the three friction discs and two middle steel discs. Inspect the wet brake clutch discs for damage and wear. Replace the parts as needed.
Remove the front steel disc with the pins and springs.
Remove the springs from the front steel disc.
Remove the pins from the front steel disc.
Lift off the cam plate.
Remove the six steel balls.
Loosen the three rubber cover screws with a Phillips screwdriver.
Remove the three rubber cover screws and washers.
Remove the rubber cover.
Hold the rear brake cam lever bolt with an 8 mm wrench and loosen the nut with a 10 mm wrench. Remove the rear brake cam lever.
Remove the rear brake camshaft. Inspect the rear brake camshaft for wear and damage. Replace it as needed.
Remove the rear brake camshaft collar. Inspect the oil seal and replace it as needed.
Installation
Install the brake camshaft oil seal so that is markings face towards the front of the vehicle. Drive the oil seal in so that it sits 4.5 ± 0.1 mm below the mating surface of the final gear case.
Lubricate the inside diameter of the oil seal, brake camshaft, and the inside of the brake camshaft collar with final gear oil.
Gear Case Oil
2002: MOBIL Fluid 424
2003 – 2011: MOBIL Fluid 424, CITGO TRANSGARD TRACTOR HYDRAULIC FLUID, or Exxon Hydraul 560
Install the rear brake camshaft collar. Install the rear brake camshaft.
Install the cam lever to the rear brake camshaft so that the two punch marks line up and the lever extends up through the swingarm. Hold the bolt with an 8 mm wrench and tighten the nut securely with a 10 mm wrench.
Fit the rubber cover into place over the rear brake cam lever. Install the three rubber cover screws and washers with a Phillips screwdriver.
Install the six steel balls.
Install the cam plate over the steel balls so that the cam post fits into the cam plate groove.
Install the two pins and springs onto the forward steel clutch plate.
Install the forward steel plate.
Install the three friction discs and steel discs in alternating fashion. Install the steel discs so that their missing tangs line up with the pins and springs on the forward steel disc.
Install the rear steel disc so that the pins fit into the holes.
Install the two down pins if they were removed. Install a new gasket. Apply a non-permanent thread locking agent (Blue Loctite) to the threads of the gasket screws. Install the two gasket screws and tighten them securely with a Phillips screwdriver.
Install the rear final gear case. See the Final Gear Case topic for more information.