The clutch or clutch control mechanism need attention when the clutch slips under load, or drags in released position. For causes of slipping clutch see "Locating Operating Troubles," Section 1C. 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.


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.

On 1964 and earlier models, remove the chain guard clutch cover (7). On 1965 models, remove the chain housing cover. 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 (8) has about 1/8 in. free movement before clutch disengages. On 1964 models, clutch lever should strike the transmission case cover. On 1965 models, clutch lever should be 1/4 in. away from starter drive housing. Turn screw (4) right for less movement and left, for more.


Adjust control cable sleeve (1) as required to maintain approximately 1/4 inch free hand lever move ment before clutch starts to disengage. To adjust, loosen adjusting sleeve lock nut (2) turn threaded sleeve out for less hand lever free play or into bracket (3) for more hand lever free play and re-tighten lock nut.

If sleeve adjustment has been all taken up or there are other indications of incorrect clutch operation such as slipping clutch, gear clash due to dragging clutch when shifting, the following adjustments should be made in the order shown.

Move end of lever on transmission forward until it becomes firm indicating that all slack in the actuating mechanism has been taken up.

Measure clearance between starter motor (7) and clutch release lever (8) which should be 3/8 to 5/8 inch. If not within this range, adjust as follows: Loosen control coil adjusting sleeve lock nut (2) (Fig. 4B-1A) and turn control coil adjusting sleeve (1) all the way into bracket. Remove chain housing cover, loosen clutch push rod screw lock nut (4) and turn screw (5) in (clockwise) to move lever (8) to the rear, or outward (counterclockwise) to move end of lever forward. When 1/2 inch clearance between lever and starter motor has been attained, tighten lock nut (4) and reinstall chain housing cover. • IMPORTANT

Chain housing must be airtight with cover reinstalled — use new cover gasket and gasket sealer.

Adjust clutch hand lever for 1/4 inch free movement before clutch starts to release by turning adjusting sleeve (1) outward and retighten lock nut (2).

Adjust clutch hand lever for 1/4 inch free movement before clutch starts to release by turning adjusting sleeve (1) outward and retighten lock nut (2). To disassemble cable from hand lever at anchor pin, turn sleeve into bracket (3) and remove cable from side slot as shown in figure 4B-1A. When reassembling cable ferrule in hand lever anchor pin with side slot, be sure slot is toward inside as shown. Earlier type pin with slotted end should have open end facing downward.


The booster type clutch hand control requires 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 bell-crank failing to return to forward position when hand lever is released, slipping clutch, or dragging clutch manifested by gear clash when shifting, the following

Figure 4B-1. Adjusting Foot Clutch Control (1964 model shown)

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