ATV / Pit bike - 90CC / 100CC / 110CC / 125CC AUTOMATIC CLUTCH REPLACEMENT

Introduction

This tutorial provides a comprehensive guide to replacing the automatic clutch in 90CC, 100CC, 110CC, and 125CC ATVs or pit bikes. Whether you're performing routine maintenance or addressing clutch issues, this step-by-step guide will equip you with the necessary knowledge and skills to complete the task effectively.

Step 1: Gather Necessary Tools and Parts

Before starting the replacement process, ensure you have the following tools and parts ready:

• Tools:

  • Socket wrench set
  • Screwdrivers (flathead and Phillips)
  • Pliers
  • Torque wrench
  • Oil catch pan

• Parts:

  • Replacement automatic clutch
  • Gasket or sealant (if needed)
  • Oil (for refilling)

Step 2: Prepare the ATV or Pit Bike

To ensure a safe and effective working environment, follow these steps:

1. Park on a Level Surface: Ensure the vehicle is on a flat surface to avoid any accidental movement.
2. Disconnect the Battery: Remove the negative terminal to prevent any electrical issues during the repair.
3. Drain the Oil: Place the oil catch pan under the engine and remove the oil drain plug to drain the oil completely.

Step 3: Remove the Clutch Cover

Follow these steps to access the automatic clutch:

1. Locate the Clutch Cover: Find the cover on the side of the engine.
2. Unscrew the Bolts: Use the socket wrench to remove all bolts securing the cover. Keep them in a safe place.
3. Gently Pry Off the Cover: Carefully use a flathead screwdriver to pry off the cover without damaging the gasket.

Step 4: Remove the Old Clutch

Now that you have access to the clutch, proceed with the removal:

1. Inspect the Clutch: Check for any visible damage or wear on the clutch components.
2. Remove the Clutch Springs: Use pliers to detach the springs holding the clutch in place.
3. Take Out the Clutch Assembly: Carefully lift the old clutch assembly out of the housing.

Step 5: Install the New Clutch

With the old clutch removed, it’s time to install the new one:

1. Clean the Housing: Wipe down the clutch housing to remove any debris or oil residue.
2. Position the New Clutch: Place the new automatic clutch into the housing, ensuring it sits correctly.
3. Reattach the Clutch Springs: Securely attach the springs to hold the clutch in place.

Step 6: Reassemble the Clutch Cover

After installing the new clutch, follow these steps to reassemble:

1. Apply Gasket or Sealant: If necessary, apply a new gasket or sealant to ensure a proper seal.
2. Reattach the Clutch Cover: Align the cover with the housing and press it into place.
3. Screw in the Bolts: Use the socket wrench to tighten the bolts securely, following the manufacturer's torque specifications.

Step 7: Refill Oil and Reconnect the Battery

To complete the process:

1. Replace the Oil Drain Plug: Securely reattach the oil drain plug.
2. Refill the Engine Oil: Pour the appropriate oil into the engine, following the manufacturer's recommendations.
3. Reconnect the Battery: Reattach the negative terminal to restore power.

Conclusion

Replacing the automatic clutch in your ATV or pit bike can greatly enhance performance and extend the vehicle's life. By following these steps, you can confidently tackle this maintenance task. After the replacement, consider testing the vehicle to ensure everything operates smoothly. If you encounter any issues, refer back to this guide or consult a professional for assistance.