Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Drive/Transmission 6-13
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CLUTCH PACK CLEANING AND
INSPECTION
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WARNING
1
WARNING
Low pressure compressed air can blow debris into your
face and eyes. Always wear eye protection or a face shield
when using pressurized air. Failure to take adequate
safety precautions could result in death or serious injury.
1. Separate the pack in to the following components:
a. Seven fiber plates.
b. Seven steel plates.
c. One narrow fiber plate.
d. One damper spring.
e. One damper spring seat
2. Wash all parts, except fiber (friction) plates and bearing
in the clutch hub/shell, in cleaning solvent. Blow dry with
compressed air.
3. Examine the clutch components as follows:
a. Check all clutch plates for wear and discoloration.
b. Inspect each steel (drive) plate 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. (0.15 mm).
4. Inspect the damper spring for cracks or distortion. Install
a
new spring if either condition exists.
5. See Figure 6-14. Check fiber plates for thickness.
a. Wipe the lubricant from the eight fiber plates (7 reg-
ular and 1 narrow) 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.
6. See Figure 6-15. Inspect primary chain sprocket and the
starter ring gear on the clutch shell. If either sprocket or
ring gear are badly worn or damaged, replace the clutch
shell. See
6.5 PRIMARY CHAIN .
7. Inspect slots that mate with the clutch plates on both
clutch shell and hub. If slots are worn or damaged,
replace shell and/or hub. See
6.5 PRIMARY CHAIN .
Figure 6-14. Measuring Friction Plates
7738
Figure 6-15. Checking Clutch Shell
(Shell Removed from Primary Shaft)
6252
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1. Primary chain sprocket
2. Starter ring gear
3. Slots on clutch hub
4. Slots on clutch shell