Buell 2002 X1, Service Manual

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6-14 2002 Buell X1: Drive/Transmission
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CAUTION
See Figure 6-16. Due to the possible damage to the bear-
ing (25), the clutch hub (23) and shell (26) assembly
should not be disassembled unless the bearing, hub or
shell require replacement. If the assembly is pressed
apart, the bearing must be replaced.
12. Disassemble clutch hub and clutch shell if necessary.
a. Remove retaining ring (27) from inboard end of
clutch hub (23).
b. Using an arbor press, separate clutch hub (23) from
assembly of clutch shell (26), bearing (25) and
retaining ring (24).
c. Remove retaining ring (24) from groove in clutch
shell (26).
d. Press on the inboard side of bearing (25) outer race
to remove bearing from clutch shell.
INSPECTION/REPAIR
1. See Figure 6-16. Wash all parts, except fiber (friction)
plates (18) and bearing (25), in cleaning solvent. Blow
dry with compressed air. Examine the clutch compo-
nents as follows:
a. Check all clutch plates for wear and discoloration.
b. Inspect each steel (drive) plate (19) for grooves.
c. Place each steel plate on a flat surface. Using a
feeler gauge, check for flatness in several places.
Replace any plates that are damaged or are warped
more than 0.006 in. (0.152 mm).
2. Check the diaphragm spring (11) for cracks or bent tabs.
Install a
new spring if either condition exists.
3. See Figure 6-19. Check fiber plates for thickness.
a. Wipe the lubricant from the eight fiber plates and
stack them on top of each other.
b. Measure the thickness of the eight stacked fiber
plates with a dial caliper or micrometer. The mini-
mum thickness must be 0.661 in. (16.789 mm).
c. If the thickness is less than specified, discard the
fiber plates and steel plates. Install a new set of
both friction and steel plates.
4. See Figure 6-20. Check the clutch shell.
a. Inspect primary chain sprocket (1) and the starter
ring gear (2) on the clutch shell. If either sprocket or
ring gear are badly worn or damaged, replace the
clutch shell.
b. Check the slots that mate with the clutch plates on
both clutch shell (4) and hub (3). If slots are worn or
damaged, replace shell and/or hub.
c. If clutch shell was removed from motorcycle, check
the bearing for smoothness. Rotate the clutch shell
while holding the clutch hub. If bearing is rough or
binds, it must be replaced.
Figure 6-19. Measuring Friction Plates
Figure 6-20. Checking Clutch Shell
6140
6252
2
1
3
4
1. Primary Chain Sprocket
2. Starter Ring Gear
3. Slots on Clutch Hub
4. Slots on Clutch Shell