2-11
2
Replacing Drive Belt
REMOVING
1. Remove the eight Phillips-head cap screws and
four cap screws securing the footrest cover to the
footrest and front and rear fenders; then remove
footrest cover.
2. Remove the cooling duct.
3. Remove the eight cap screws securing the drive
clutch cover; then remove the cover. Account for a
gasket and two alignment pins.
NOTE: The gasket does not need to be removed
unless it is being replaced or unless additional
servicing is being done requiring its removal.
4. Remove the nut securing the stationary drive
sheave to the crankshaft; then remove the station-
ary drive sheave. Account for a washer, kick
starter ratchet, and cooling fan.
CD621
5. Open the movable sheave on the driven clutch
assembly with a suitable pry bar or wedge; then
remove the drive belt.
CD624
INSTALLING
1. If removed, place the gasket and two alignment
pins into position on the crankcase.
2. Spread the faces of the driven clutch with a suit-
able pry bar or wedge; then when the faces are
separated, insert the drive belt.
CD624
NOTE: If the drive belt has an arrow stamped on
the outer face, it should point forward (direction of
rotation).
3. Pinch the drive belt together near its center and
slide the stationary drive sheave over the crank-
shaft. Install the washer, kick starter ratchet, and
cooling fan. Secure the stationary drive sheave
with a nut (threads coated with red Loctite #271).
Tighten the nut to 27.5 ft-lb.
CD623
CD619
4. Rotate the drive belt and sheaves until the drive
belt is flush with the top of the driven clutch.
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