Power Train - Gear Repair - 126
POWER TRAIN - GEAR REPAIR
- Clamp locking pliers (A) to movable (inboard) sheave.
- Using spring scale (B) hooked into jaw of locking pliers
as close to sheave edge as possible, measure the force
required to rotate the movable sheave. Force measurement
is taken while returning cam to closed position right before
buttons (C) touch.
Specification:
Standard Wrap Brown Spring...... 22 - 20 N (5 - 9 lb)
Standard Wrap Green Spring.... 62 - 80 N (14 - 18 lb)
NOTE: Standard torsion spring (D) installation sets
spring tab in hole ì2î in moveable sheave half. Due to
variations in the spring rate of the torsion spring, the
spring tab may be factory set in holes ì1î or ì3î.
Results:
- Spring force within specification; secondary clutch is
OK.
Check engine rpm and performance. - Spring force less than specification, up-shift will be
faster and engine load greater, reducing engine rpm and
response time. Check spring position, set spring tab in next
higher number hole, (i.e. move from hole “2” to ”3”) and re-
check spring force. Replace spring if still not within
specifications. - Spring force higher than specification, up-shift or
acceleration will be slower, reducing engine load,
increasing engine rpm and response time. Check spring
position, set spring tab in next lower number hole, (i.e.
move from hole “2” to ”1”) and recheck spring force.
Replace spring if still not within specifications.
Repair
Primary Clutch Removal
- Remove black plug in front of rear tire on left side of
frame. - Remove drive belt.
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- Remove plastic plug from clutch cover.
- Remove clutch mounting bolt and washers.
- Use JDG813-1A Clutch Removal Tool (B). Thread puller
into clutch and against crankshaft. Tighten until clutch pops
free from crankshaft taper.
NOTE: An air impact wrench works well to remove the
primary clutch.
- Install clutch in reverse order of removal. Tighten clutch
bolt to 40 ± 8 N•m (24 – 35 lb-ft).
Primary Clutch Repair
- Remove clutch cover bolts. Remove cover. (Cover
should pop off; do not pry on cover.) - Install JDG813-3 Tapered Holding Tool (A) and retain it
with a M10 X 1.5 X 150 mm hex-head bolt. - Place an index mark on the spider and movable sheave
with black marker.
IMPORTANT: Avoid damage! Lightly grease (A) end
of puller (B) to help prevent puller wear. To prevent
clutch thread damage, DO NOT thread bolt in any
farther than necessary to remove clutch.
IMPORTANT: Avoid damage! Always use JDG813-
Spanner Wrench (B) to remove spider. Unequal
pressure on clutch towers could cause stress
fractures or break them off. A medium strength
thread lock is used on spider threads.
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A
B