How to Change TVS NTORQ Clutch Shoes — Step by Step
Indruction
Hello friends, welcome to Rajesh Technical Blog. Today I will tell you about “TVS NTORQ clutch shoe changing process — step by step”.
This guide is written for NTORQ owners, delivery riders, and beginner mechanics who want a clear, safe, and practical clutch-shoe replacement procedure.
Note / Safety first: Always work on a cool scooter, park on a flat surface, engage center stand, and disconnect the battery before opening the CVT/variator or clutch cover. Wear gloves and eye protection. (Procedure references: TVS service manual and service guides).
What is a clutch shoe and when to replace
The clutch shoe (liner) is the friction surface inside the clutch that engages the clutch bell and transfers engine power to the wheel. TVS recommends inspecting/replacing clutch shoes as part of scheduled transmission/CVT service — typically inspect and replace when worn (manufacturer service schedules list clutch shoe replacement intervals around the long-interval service points; check your model’s manual).
Tools & parts you will need
- Socket set and ratchet (usually 8–17 mm sockets)
- Impact/long breaker bar for variator/clutch nut (or proper holding tool)
- Screwdrivers (Phillips & flat)
- Torque wrench (recommended)
- Rubber mallet or puller (if needed)
- Pliers / circlip tool (if applicable)
- Clean rags and an old toothbrush
- New genuine TVS NTORQ clutch shoe set (or good aftermarket replacement)
- Grease for splines (small amount)
- CVT cleaner / degreaser (optional)
(Reference procedure and part notes from TVS service guides and practical repair videos).
Step-by-step clutch shoe changing process
1) Prepare the scooter
- Park on center stand on level ground and turn OFF ignition.
- Remove battery negative terminal (safety).
- Remove under-seat storage or panels that block access to the CVT side (right side).
(Always follow model-specific panel removal — see service manual).
2) Remove the CVT/clutch cover
- Locate and remove bolts holding the CVT/clutch outer cover. Keep bolts in order.
- Gently pry off the cover — beware of the cork gasket or rubber seal; inspect and keep clean.
- If cover is stuck, tap lightly with rubber mallet.
(You will now see variator, drive belt, and clutch assembly).
3) Remove the drive belt / variator (if needed)
- Loosen variator nut while holding the variator (use proper holding tool) — many prefer an impact or a long breaker while holding the crank.
- Remove outer variator face and variator rollers/weights to free the belt. Note roller orientation and order.
- Slide off the drive belt. Keep the belt clean — inspect for cracks/wear (replace if worn).
(Some mechanics remove belt first; others remove clutch side first — either way keep parts organized.)
4) Access the clutch shoes
- On the clutch bell side, remove the big nut that holds the clutch bell (use appropriate socket). The bell may be tight — use breaker/impact and hold the wheel or hub if needed.
- Carefully slide off the clutch bell. Inside you will see the clutch shoes attached to the clutch hub.
- Inspect clutch bell inner surface (for glazing or heat spots) and the clutch shoe friction surface for wear, glazing, or cracks. If bell is glazed, polish lightly with fine sandpaper; if deeply scored, replace bell.
5) Remove old clutch shoes
- Depending on design, clutch shoes may be retained by springs or pins. Unhook/remove the return springs (note their orientation).
- Remove each clutch shoe assembly carefully. Keep springs and pins separately.
- Clean the hub and surrounding area with a rag or CVT cleaner; remove dust and oil. Never leave oil on friction surfaces.
6) Inspect & prepare new parts
- Compare new shoes to old ones (thickness, lining). If new shoes match, proceed.
- Lightly sand any sharp edges on new shoes and make sure mating surfaces are clean.
- Check clutch hub and bushing for wear — if worn excessively, replace hub/bush.
- Apply a very small amount of high-temp grease to the hub splines where recommended (avoid grease on friction linings).
7) Fit new clutch shoes
- Fit shoes into place, secure pins/retainers and reattach springs in original orientation. Ensure shoes move freely on their pivots and springs are seated correctly.
- Check free movement by pushing shoes outward gently — they should retract smoothly.
- Reinstall clutch bell over the shoes, ensure no rubbing while bell is in place.
8) Reassemble variator, belt and covers
- Refit the drive belt (replace if worn) and reassemble variator rollers/weights in correct positions.
- Tighten variator nut to specified torque (refer service manual torque values where available). Use torque wrench if possible.
- Refit CVT/clutch outer cover with gasket and tighten bolts in cross pattern. Reconnect battery terminal.
9) Test & bed-in
- Start the scooter, idle for a minute and listen for unusual noises.
- Take a short test ride at low speeds, avoid heavy throttle for first 50–100 km to bed-in friction surface.
- After initial run, recheck bolts and make sure no overheating, slipping, or abnormal vibration occurs.
Common signs that shoes need changing
- Major loss of pickup / slow acceleration
- Excessive slipping or burning smell from CVT area
- Clutch engagement at unusually high rpm
- Visible thinning or cracking of lining
TVS service schedule also lists inspection/replacement intervals for clutch shoes — check your owner manual for the recommended km.2025/12/electricity-e-bike-repairing-process
Tips & precautions
- Use genuine TVS replacement shoes where possible for correct fit and life.
- Never contaminate friction surfaces with oil/grease. Clean hands and tools.
- If clutch bell is glazed, deglaze gently with fine sandpaper or replace if badly scored.
- If you are not confident with heavy nuts, use proper pullers and torque tools or visit an authorized service center.
- Keep a service video or manual open for visual reference — many good walkthrough videos exist for NTORQ clutch shoe change.
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