Adjusting Clutch

If the clutch slips after adjusting clutch controls, increase spring tension on the three clutch spring guide stud nuts (6, Fig. 4B-1). Tighten all three nuts one-half turn at a time until clutch holds. Test after each half turn by cranking the engine. Usually a clutch that holds without noticeable slipping when cranking the engine will hold under normal road conditions. Do not increase spring tension any more than is necessary to make clutch hold.

A new clutch is assembled so the distance from inner edge of spring collar (2, Fig. 4B-4) to the surface of the outer disc (9) is exactly 31/32 in. If springs are compressed so this distance is 7/8 in. or less, the clutch probably cannot be fully disengaged.

When clutch will not hold without tightening beyond this limit, disassemble the clutch for inspection of the clutch discs. Discs may be worn or oil soaked and in need of replacement or washing.

DISASSEMBLING CLUTCH (Fig. 4B-5) Remove outer chain guard.

Remove push rod adjusting screw lock nut (1). Place a flat washer about 1/8 in. thick with 1-3/4 in. outside diameter and 3/8 in. hole over the adjusting screw (2). Replace lock nut and turn down until three spring tension adjusting nuts (3) are free. The nuts may then be removed and the spring collar-springs-outer disc assembly (4, 5 and 6) may be slipped off clutch hub dowels and studs as shown in Fig. 4B-4. Do not disassemble these parts unless necessary for spring, spring collar or outer disc replacement.

Remove spring disc (7). Remove three steel discs (8) and three lined friction discs (9).

Remove engine sprocket or compensating sprocket as described in "Stripping Motorcycle for Transmission Repair," page 4A-2, step 4.

Remove clutch shell (10) and primary chain from clutch hub.

Pry back ear on clutch hub nut lock washer. Remove clutch hub nut (11) using Clutch Hub Nut Wrench, Part No. 94645-41. Thread is left hand. Loosen nut by striking wrench handle several sharp blows with a mallet. Remove clutch hub nut lock washer (12) and strip push rod cork oil seal (13) off push rod.

Remove clutch hub (14) using Clutch Hub Puller, Part No. 95960-41. Turn tool center bolt back until puller plate may be slipped over clutch hub studs and against ends of clutch hub pins. Secure puller

1. Clutch actuating lever

2. Clutch cover

3. Push rod adjusting screw

4. Push rod adjusting screw lock nut

5. Clutch lever rod plate with the three clutch spring guide stud nuts. Turn down tool center screw until clutch hub breaks free from gear box shaft taper. Remove clutch hub key (15).

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