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pulling the gear off the shaft. A disposable spring retainer is used to hold the waterpump shaft assembly into transmission case.
Being careful not to damage waterpump shaft, use a screwdriver to pry the retaining ring out of the engine case. It will be necessary
to bend or break the retaining ring to remove it. Once the retaining ring has been removed, the water pump shaft and bearings can be
pushed out of the case from the impeller side. Push the waterpump seal out from the inside of the case. Inspect the water pump shaft
for bending, wear or damage. Make sure the bearings turn freely and do not have excessive play or any roughness. If water pump is
serviced, always replace waterpump seal and retaining ring with new ones.
To install waterpump assembly, lubricate seal and press into place from outside of case. Install bearings onto shaft and lubricate
shaft and bearings with oil. Push shaft into case from inside, being careful not to damage the seal. Push in new retaining ring using a
deep socket that fits over waterpump shaft. Do not use excessive force to install retaining ring, or you may damage it. Install gear
onto shaft and replace snap ring. Install impeller by threading on by hand in a clockwise direction. Do not over-tighten and strip
impeller threads. Install a new o-ring into water pump cover and install bolts. Snug bolts, but do not over-tighten or housing will leak.
17. Clutch & kickstarter assemblies
The works models use a custom 3 shoe racing clutch assembly, while recreational and standard models use a 2 shoe clutch.
To
maximize clutch life and ensure optimum operation, change the oil frequently, after every race or at the end of each riding
day. The clutch will need to be removed, disassembled and cleaned on a regular basis to maintain proper operation
. Wear par-
ticles from the clutch shoes can clog the spring washers and prevent full engagement as well as damaging the spring washers over
time. A slipping clutch will rapidly wear out the shoes and may damage the drum. Regular oil changes and cleaning of the clutch
will help prevent problems.
The Maxima MTL 75 transmission oil has special additives to prolong clutch life and is strongly
recommended.
Three shoe clutch
- To service clutch, begin by removing brake lever pivot bolt using a 15mm wrench on the pedal bolt and a
13mm wrench on pedal bolt nut. Detach pedal spring, and lay pedal to side. Do not kink brake cable. Remove seat, fuel tank and
spark plug. Insert piston stop tool. Drain oil, or be prepared to catch oil when sidecover is removed. Remove 6 case bolts using 5mm
allen wrench. Hold kickstarter and use it to gently rock cover and pull it off. Be cautious not to tear clutch cover gasket, it can usual-
ly be reused many times. Check the teeth on the half moon shaped kickstarter gear attached to kickstarter shaft for wear or damage.
Use your fingers to push the spring retainer on end of crankshaft inward, exposing the retaining “E” clip. Use a small screwdriver to
pry the clip off the shaft. Be careful not to lose clip, replace if worn, loose, or bent. Remove retainer, spring, and starter gear. Make
note of gear, clip, retainer and spring condition, replace if any noticeable wear or damage. Closely inspected the ratcheting teeth on
the clutch nut and kickstarter gear for wear or damage. These parts wear with usage and will require eventual replacement. Use care
when kickstarting to prolong their life. Push kickstarter down gently until engaged before kicking for best results.
Rotate clutch nut slowly counter-clockwise until piston contacts stop, then use a 19mm wrench or socket to remove clutch nut and
washer, if installed. Most machines will have a washer under clutch nut, but not all. If a washer is not used, make sure that nut does
not bottom on end of threads before tightening against clutch hub – take measurements to make sure. Under no circumstances use air
impact wrench in conjunction with the piston stop or piston damage will result! Do not use heat to remove clutch nut or other clutch
Clutch and kickstarter driven gear assembly.
Note that holes in sides of clutch shoes face outward.
Use proper puller to remove clutch assembly without
damage! Lubricate puller threads before use.
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