Replacing Clutches on Terry the Tomos A3 Golden Bullet | JAM#23

After blowing this thing up again last year, its time to fix it again.
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[@amhurford]

Great video, thank you so much. Very informative.
I mention the following for anyone it can assist: Keep an eye out for shims as the case comes off, they are on all three shafts or stuck to the bearing in the case. Also, there is another shim (0.3mm) that sticks itself discreetly to the back of first gear clutch hub. The clutch shoes really are the weak part of the A3 engine. They are so fragile and will fracture and crack in time with use. The springs are a pure nightmare to refit without factory tool number: 731.798. The impact wrench is a god sent for undoing the clutch hub nut (as in the video.). The torque setting for re-tightening the clutch nut is: 18 pounds/foot. A couple quick pulls on the trigger of the impact wrench on lowest setting will do, ensuring the locking tab washer is also bent to lock the nut. Other methods of getting the clutch nut off is using a car oil filter strap wrench. It will hold the clutch drum if you wrap the drum with a good amount of masking tape to hold the strap in place to undo or re-tighten the nut. Another trick of the trade is to take the spark plug out and push cord or thin rope down the spark plug hole to pack out the combustion chamber to lock the piston so the engine can't turn. I used a four inch, three legged puller to get the clutch off. It makes the job a doddle. The factory manual and Haynes drawing are obscure to which way around the first gear toothed spring plate is. The outside edges of the spring plate should rest against the outer edge of the clutch hub. The second gear clutch does not have a spring plate. When re-fitting the clutch drum, if it won't go on enough to get the spring washer, locking washer and nut on, use a small socket resting on the first gear clutch hub to gently tap it onto the shaft until the nut will go on. Never tap the clutch shoes or they will break. Tighten the clutch nut to push the clutch drum onto the shaft then torque the nut.

[@BobsBikingAdventures]

Excellent use of percussive persuasion and precision angle grinding. Looks fun!