General

The clutch or clutch control mechanism needs attention when the clutch slips under load, or drags in released position. For causes of slipping clutch see "Locating Operating Troubles," Section 1C, items 93, 94 and95. If clutch drags or fails to release, see items 96, 97, 98, 99 and 100. If clutch chatters when being engaged, see 101 and 102. Before disassembling clutch when repair is indicated, readjust gear shifter control and clutch spring tension. It is not necessary to remove transmission from chassis to adjust or repair clutch.

ADJUSTING FOOT CLUTCH CONTROL (Fig. 4B-1)

With foot pedal (1) in fully disengaged position (heel down), the clutch lever (8) should strike the transmission case cover. Adjust length of the foot pedal rod (3) to just clear the foot pedal bearing cover (2) so the rod is not bent down by the bearing cover.

Remove the chain guard clutch cover (7), move the foot pedal (1) to a toe down or fully engaged position, loosen the lock nut (5) and readjust the push rod adjusting screw (4) with a screwdriver so that the end of the clutch lever rod (8) has about 1/8 in. free movement. Turn screw (4) right for less movement and left, for more.

1. Foot pedal

2. Foot pedal bearing cover

3. Clutch lever rod

4. Push rod adjusting screw

5. Push rod adjusting screw lock nut

6. Spring tension adjusting nuts (3)

7. Clutch cover

8. Clutch actuating lever

Figure 4B-1. Adjusting Foot Clutch Control

ADJUSTING HAND CLUTCH CONTROL (Fig. 4B-2)

Normally, the only attention the clutch hand control requires is occasional adjustment of control coil adjusting sleeve (1) and the clutch lever rod (5) to maintain the correct amount of free movement for hand lever on handlebar and clutch actuating lever.

If major readjustment is indicated by hand lever becoming hard to operate, clutch control booster bellcrank failing to return to forward position when hand lever is released, slipping clutch, or dragging clutch manifested by gear clash when shifting, the following adjustments should be made:

Loosen clutch lever rod lock nut (7) and unscrew clutch lever rod (5) far enough so clutch actuating lever (1, Fig. 4B-3) has about 1/2 in. free movement. Move end of actuating lever forward to a position where it becomes firm indicating that all slack in the actuating mechanism has been taken up. The distance from the foot shifter housing on transmission to the outer edge of chamfered slot in lever (1) should be 4-1/4 in. as shown in Fig. 4B-3. If necessary, readjust to obtain this measurement as follows:

Remove clutch cover (2, Fig. 4B-3), loosen push rod adjusting screw lock nut (4) and turn push rod adjusting screw (3) to the right to move lever to rear; to left to move lever forward. When correct position of lever has been attained, tighten lock nut and install clutch cover.

Refer to Fig. 4B-2. Loosen control coil adjusting sleeve lock nut (2) and turn in adjusting sleeve until clutch hand grip has an inch or more free play.

Loosen bell crank adjusting screw lock nut (4) and tighten bell Crank adjusting screw (3) until bell crank (8) fails to go across top dead center, as shown, when moved back and forth by hand.

Loosen clutch booster spring tension upper adjusting nut (13) as far as it will go.

Turn out bell crank adjusting screw a little at a time until bell crank moves over top dead center and remains in that position when released. Move bell crank by hand, not with control hand lever. Bell crank should find locked position at about 1/8 in. over dead center. Tighten adjusting screw lock nut (4).

Adjust clutch lever rod (5) so clutch actuating lever has 1/16 in. free movement. Tighten clutch lever rod lock nut (7).

Turn adjusting sleeve (1) upward until end of clutch hand lever has 1/2 in. free movement before releasing pressure is applied to clutch. Tighten lock nut (2).

1. Control coil adjusting sleeve

2. Control coil adjusting sleeve lock nut

3. Bell crank adjusting screw

4. Bell crank adjusting screw lock nut

5. Clutch lever rod

6. Clutch control booster spring

7. Clutch lever rod lock nut

8. Clutch control booster bell crank

9. Shifter rod end bolt

10. Shifter rod end

11. Shifter rod end lock nut

12. Clutch booster spring tension adjuster

13. Clutch booster spring tension upper adjuster nut

14. Clutch booster spring tension lower adjuster nut

15. Gear shifter lever

16. Gear shifter foot lever and rubber pedal

17. Foot lever cover mounting stud

18. Grease gun fittings (2)

19. Shifter rod

20. Foot lever positioning mark

21. Foot lever clamping slot

Figure 4B-2. Adjusting Hand Clutch Booster

Depress clutch hand lever fully. Tighten clutch booster spring tension lower adjusting nut (14) until hand lever remains depressed. Slowly loosen lower adjusting nut enough to allow hand lever to return to fully extended position. Tighten upper adjusting nut (13).

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