E-Z-GO FLEET 1999, Technician'S Repair And Service Manual

Page: 107 / 188

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
AwARNINGA
Disable the electrical
system before attempt­
ing to remove the drive
belt to prevent the engine from inadvertently starting.
To prevent burns, be sure that the engine and exhaust
components have cooled before attempting any ser­
vice.
Do not allow fingers to become trapped between the
belt and clutch sheave.
To prevent possible injury that could result from a
broken socket, use only sockets designed for use
with an impact wrench. Never use a socket intended
for use with hand tools.
Remove the drive belt (1) and the starter belt. (Refer to
'Removing The Drive Belt' procedure elsewhere in this
section.)
Remove the clutch bolt (2), lock washer (3) and pilot
washer (4) (Ref Fig. 2 on page J-2). Insert a greased
clutch puller and tighten (clockwise) using an impact
wrench which will remove the clutch from the engine
crankshaft.
I
NOTE
I
In some extreme cases, the clutch may not
.
. separate from the crankshaft. Remove the
clutch puller and fill the cavity with grease. Replace the clutch
puller and tighten it with the impact wrench. The combined
mechanical and hydraulic effect will remove the clutch. Remove
all excess grease.
Drive Clutch Installation
CAUTION
Do not install the bolt with an impact
wrench.
Clean both the engine crankshaft and the drive clutch
bore. Slide the clutch onto the engine crankshaft and
rotate the clutch while lightly pushing the moveable
sheave in and out several times to seat the clutch with
the tapered crankshaft (Ref Fig. 2 on page J-2).
Install the lock washer (3) and the large pilot washer (4)
onto the clutch bolt (2).
Apply thread sealant to the threads of the clutch bolt and
install and tighten to 40 - 44 ft. lbs. (54 - 60 Nm) torque.
Driven Clutch Removal
Tool List Qty. Required
External snap ring pliers ............................................. 1
Socket, 5/8", 1 /2" drive ................................................ 1
Ratchet, 1/2" drive ....................................................... 1
Thread locking sealant.. ........................................... AR
Phillips screwdriver ..................................................... 1
Torque wrench, 1 /2" drive, ft. lbs . ................................ 1
Remove the drive belt (1) (Refer to 'Removing The Drive
Belt' procedure elsewhere in this section).
Remove the clutch bolt (5), the lock washer (6) and the
pilot washer (7) and slide the clutch from the rear axle
input shaft.
Driven Clutch Repair
I
NOTE
I
Parts must be reassembled in same position as
.
· their original position. Mark all components to
facilitate accurate reassembly.
Some minor field repairs may be made to the driven
clutch. Remove the retaining ring (8) and remove the
torque ramp (Ref Fig. 2 on page J-2). Remove the spring
(10) and the moveable sheave (11 ).
Inspect the shaft for signs of wear and inspect the bush­
ings for signs of deterioration. If there is wear to the point
of causing vibration, the clutch must be replaced.
Torque Ramp Buttons
Remove any fragments and dirt. Remove the ramp but­
ton (12) by removing the screw (13) (Ref Fig. 2 on page
J-2). The buttons are replaced by inserting a new button
and screw and tightening firmly. It is good required to
replace all buttons as a set.
Driven Clutch Assembly
Assemble the moveable sheave (11) to the fixed sheave
(14) and insert the spring (10) in the pilot hole in the
moveable sheave (Ref Fig. 2 on page J-2). Insert the
other end of the spring in the torque ramp (9) and rotate
the ramp counterclockwise 140
°
before engaging the
splines and inserting the retaining ring (8).
Driven Clutch Installation
Coat the rear axle input shaft with a light coating of anti­
seize compound and slide the clutch onto the shaft (Ref
Fig. 2 on page J-2). Install the lock washer (6) and pilot
washer (7) to the clutch bolt (5) and apply thread sealant
to the threads of the clutch bolt. Install the bolt and
tighten to 14 - 17 ft. lbs. (19 - 23 Nm) torque.
DRIVE BELT
Removing the Drive Belt
With the vehicle on level ground, remove the drive belt by
pulling the belt upwards which will cause the driven
clutch sheaves to open and loosen the belt tension (Ref
Repair and Service Manual
Page J-3