Clutch

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 1. 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 HAND CLUTCH LEVER (Figure 4-2) Adjust control cable sleeve (1) as required to maintain approximately 1/4 in. free hand lever movement before clutch starts to disengage. To adjust, loosen adjusting sleeve locknut (2), turn threaded sleeve out for less hand lever free play or into bracket (3) for more hand lever free play and retighten lock nut to 25 ft-lbs torque.

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

HAND

LEVER ANCHOR PIN

HAND

LEVER ANCHOR PIN

Figure 4-1. Clutch Hand Lever Cable

See Figure 4-2. Move end of lever (7) on transmission forward until it becomes firm, indicating that all slack in the actuating mechanism has been taken up.

Measure clearance as shown In Figure 4-2. If not within this range, adjust as follows:

Loosen control coil adjusting sleeve locknut (2, Figure 4-2) and turn control coil adjusting sleeve (1) all the way into bracket. Remove chain housing cover, loosen clutch push rod screw locknut (4) and turn screw (5) outward. Turn adjusting sleeve (1) outward until proper lever (7) clearance is obtained. Turn screw (5) inward until contact is made with push rod. Then back off 1/8 turn. Tighten locknut (4) and reinstall chain housing cover.

NOTE

A gage for setting clearance can be made out of light gauge sheet metal. Cut a strip 13/16" wide and remove all burrs. Make a 90° bend about 1/4 inch from one end. Hook the gage over the clutch cable and between the transmission lever and the transmission tower.

IMPORTANT

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

To disassemble cable from hand lever at anchor pin, turn sleeve into bracket (3) and remove cable from side slot as shown in figure 4-1. When reassembling cable ferrule in hand lever anchor pin with side slot, be sure slot is toward inside as shown.

Adjust clutch hand lever for 1/4 in. free movement as described above.

ADJUSTING CLUTCH

If the clutch slips after adjusting clutch controls, increase spring tension on the three clutch spring guide stud nut! (6, figure 4-2). Remove clutch cover and tighten all three nuts one-half turn at a time until clutch holds. Test aftei 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 nol 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, figure 4-3) to the surface of the outer disc (8) is exactly 1-1/32 in. If springs are compressed so this distance is 7/8 in. or less, the clutch probably cannot be fully disengaged. Check this dimension at several points to make sure that releasing disc is parallel with plates.

Re-adjust cable and lever (7).

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 (Figure 4-4)

Remove primary chain housing cover.

Figure 4-2. Adjusting Clutch

EARLY 1979 AND EARLIER

1. Clutch cable adjusting sleeve

2. Sleeve locknut

3. Bracket

4. Clutch push rod adjusting screw lock

5. Clutch adjusting screw

6. Clutch spring adjusting nuts

7. Clutch release lever

EARLY 1979 AND EARLIER

Figure 4-2. Adjusting Clutch

Figure 4-3. Removing Clutch

1. Flat washer (tool)

2. Spring collar

4. Clutch hub nut

5. Friction discs (5)

7. Spring tension adjusting nuts (3)

8. Outer disc

1.

Push rod adjusting screw

6.

Outer disc (pressure

12.

Clutch hub

lock nut

plate)

13.

Clutch hub key

2.

Adjusting screw

7.

Steel disc (4)

14.

Bearing plate spring (3)

3.

Spring tension adjusting

8.

Friction disc (5)

15.

Bearing plate

nut (3)

9.

Clutch shell

16.

Bearing retainer

4.

Spring collar

10.

Clutch hub nut (left hand thd.)

17.

Bearing roller

5.

Springs (10)

11.

Hub nut lock washer

18.

Hub nut seal

Figure 4-4. Clutch Assembly — Exploded View

Figure 4-4. Clutch Assembly — Exploded View

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 figure 4-3. Do not disassemble these parts unless necessary for spring, spring collar or outer disc replacement.

Remove steel discs (7) and lined friction discs (8).

Remove primary chain adjuster.

Remove engine compensating sprocket nut.

Remove clutch shell (9) compensating sprocket and primary chain from clutch hub.

Pry back ear on clutch hub nut lock washer. Remove clutch hub nut (10) using Clutch Hub Nut Wrench, Part No. 94645-41. Thread is left hand. Remove clutch hub nut lock washer (11).

Remove clutch hub (12) using Clutch Hub Puller, Part No. 95960-41 A. Turn tool center bolt back until puller plate may be slipped over clutch hub studs and against ends of clutch hub pins. Secure puller 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 (13).

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