11. To remove the lock nut:
Straighten the lock washer tab. I fooled around for a while trying to come up with materials to build a nice elegant holding tool like Honda’s, but finally just made due without. I put a 1 ¼ inch socket on a breaker bar, attached it to the lock nut, had my wife hold the rear brake, and I smacked the breaker bar with a two foot long two by four. The nut came loose the first time. Then it is just a matter of unscrewing the nut the rest of the way, removing the locking tab, and sliding the clutch assembly off of the shaft.
12. The clutch pack has to be disassembled by pressing on the clutch spring enough to make it possible to remove the snap ring.
12.1 I did find two friction disks that were destroyed. So, I ordered the clutch kit on EBAY from Saber Cycles. These clutch disks were not Honda OEM but seem to work just fine. There are 9 disks in the clutch:
1 each Honda PN 22202-MT8-000
6 each Honda PN 22201-MT8-000
2 each Honda PN 22203-MT8-000
The kits from saber cycles only have 7 disks. They specify that their disks are replacements for 22202-MT8-000 and 22201-MT8-000. So, I complained via email and they immediately sent two more disks, but they were exactly the same as the other 6 that replace 22201-MT8-000.
As I looked the disks over, there was only one that was a different size (22202-MT8-000). PN's 22201 and 22203 were only different with regards to the face pattern. The other after-market disks did not match the honda disk face patterns at all. So, I elected to install the disks anyway and take my chances. This gave me all new aftermarket disks.
13. After soaking the disks in 4 stroke MC oil I installed them in the clutch pack and installed the clutch pack back into the bike. Note: This is a real pain in the a... because all of the disks have to be perfectly aligned. The manual says to put the whole thing together without the clutch spring, slide it into the basket, slide it back out and install the spring without moving the disks. Ya right!! The way I did it was like they said, but there is no way to get it perfect. So, after getting the clutch pack started in the clutch basket far enough to encounter the first disk that is out of alignment. Then, using a strip of wood and a mallet against the disk teeth, I bumped the teeth just enough to line them up. I was able to get to all of the teeth by rotating the rear tire to turn the clutch basket (bike in gear of course). Place the center nut on the shaft and use it to slowly and carefully pull the clutch pack into the basket as each disk is aligned. If you make a mistake here you take a chance on breaking something expensive.
14. From here on just assemble in reverse order. Sorry I didn't take pictures of the clutch pack when it was out. Just got in a hurry and forgot.
Present Bike: \'90 GL1500
Previous Bike: \'85 GL1200
Previous Bike: \'81 GL500I