Buell 2002 S3T, Service Manual

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2002 Buell S3T: Drive/Transmission 6-15
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ASSEMBLY
Clutch Pack
1. See Figure 6-16. Install the clutch pack, which consists
of eight fiber plates (18), six steel plates (19) and a
spring plate (20), into the clutch hub (23). The order of
plate assembly, from inboard to outboard, is as follows:
F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F
(F = Fiber plate, St = Steel plate, Sp = Spring plate)
CAUTION
See Figure 6-15. Turn compressing tool handle (5) only
the amount required to install spring seat (9) and snap
ring (8). Excessive compression of diaphragm spring (6)
could damage clutch pressure plate (7).
2. Place assembly of spring seat, new snap ring, dia-
phragm spring, pressure plate, adjusting screw compo-
nents and compressing tool onto clutch hub and against
clutch pack.
a. See Figure 6-21. Align square openings of pressure
plate and diaphragm spring (1) so that the assembly
can be installed over prongs (2) of clutch hub.
b. Position spring seat (5) with its larger O.D. side
toward diaphragm spring (1).
c. See Figure 6-15. Place a wrench on the clutch
spring forcing screw (1) flats to prevent the forcing
screw from turning.
d. Turn compressing tool handle (5) clockwise until dia-
phragm spring (6) compresses just enough to install
spring seat (9) and
new snap ring (8) into the
groove in clutch hub prongs.
e. With snap ring positioned against outboard side of
spring seat, and fully seated in groove of clutch hub,
carefully loosen and remove compression tool.
Primary Drive
1. See Figure 6-22. Assemble clutch hub and shell if nec-
essary.
a. Press new bearing (3) in clutch shell (4). Secure
bearing with a new retaining ring (2).
b. Press inboard end of clutch hub (1) into shell bear-
ing (3). Secure with
new retaining ring (5) on end of
hub.
2. Assemble pressure plate hardware.
a. See Figure 6-17. Place bearing inside release plate.
Insert adjusting screw (4) through bearing and
release plate (2). Secure with
new retaining ring (3).
b. See Figure 6-21. Position diaphragm spring (1) with
its concave side facing toward pressure plate onto
pressure plate assembly.
c. Insert adjusting screw assembly (4) into pressure
plate. Secure with large retaining ring (3).
d. Position spring seat (5) with its larger O.D. side
toward diaphragm spring.
3. Attach tools to compress clutch diaphragm spring. See
Step 2 of
CLUTCH PACK under 6.5 PRIMARY DRIVE/
CLUTCH . Do not tighten compressing tool against dia-
phragm spring at this time.
4. Install the clutch pack. Follow all instructions of CLUTCH
PACK under 6.5 PRIMARY DRIVE/CLUTCH .
Figure 6-21. Spring Seat Installation
Figure 6-22. Clutch Hub and Shell Assembly
5
6253
1
2
1. Diaphragm Spring (Pressure Plate Below)
2. Prongs on Clutch Hub
3. Retaining Ring
4. Adjusting Screw Assembly
5. Spring Seat
4
3
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5
4
3
2
1
1. Clutch Hub
2. Retaining Ring
3. Bearing
4. Clutch Shell
5. Retaining Ring