Different thickness flat washers ranging from .030˝ to .070˝ are available from Action Racing. Thicker washers will raise the
engagement RPM, thinner washers will lower it.
To check the clutch engagement speed, you will need an inductive tachometer, which gets its signal from the spark plug wire.
Ignition testers are available from SnapOn Tools and other tool merchants. A company call Northern Hydraulics has an inexpensive
unit for under $50 which works reasonably well.
Reassemble clutch by putting spring and flat washers on shoulder bolt. Insert bolt and washer assembly into clutch shoe. Degrease
bolt threads and clutch hub threads with contact cleaner or brake cleaner. Apply red threadlocker sparingly to bolt threads and screw
bolt into clutch hub. Tighten shoulder bolt to
10 Nm
. Repeat procedure for other 2 shoes. Remove any threadlocker from bore of
clutch hub. If drum was removed, replace drum making sure bearing or bushing is in place. Install washer against drum, making sure
the cupped side is out per diagram III-32. Install woodruff key into slot in crankshaft and press firmly into place. Make sure key is
level. Place the clutch assembly on crankshaft and make sure slot in clutch hub aligns with woodruff key. Note recessed side of
clutch hub faces out, and side with boss faces clutch drum. Press hub firmly onto shaft with hand pressure, then install clutch nut and
washer (if used) and turn until piston contacts piston stop. Torque to 42 ft/lbs. Use a small amount of red threadlocker on clutch nut.
Check end of crankshaft for wear. Make sure starter gear will slide over end of shaft. Remove any burrs as required with a file, cov-
ering clutch and cases with a rag to make sure filings do not enter cases or contaminate clutch. Install starter gear, spring and spring
retainer. Push retainer inward and install a new clip into groove in end of crankshaft. Make sure clip is seated and that spring retainer
encircles clip when it is released. See diagram III-29.
Fit gasket to side cover, making sure two dowel pins
are in place. Fit cover to side of engine. Install 6 case
bolts loosely, then rotate kickstarter until it engages the
starter gear. Hold kickstarter in position and torque case
bolts to
10 Nm.
A piece of wire attached to the footpeg
can be used to hold kickstarter in position while tight-
ening case screws. Check operation of kickstarter. If
kickstarter binds or fails to return to upright position,
loosen 6 case bolts and push side cover firmly upwards
& rearward using a large screwdriver in addition to
holding kickstarter in the engaged position, then tighten
case bolts.
Remove piston stop and replace spark plug. Install
brake pedal, fuel tank and seat. Fill transmission with
oil. Check for oil leaks and reposition or replace gasket
as required.
Note:
consider using threadlocker to attach case dowels
to side cover to prevent loss and ensure the gasket
comes off with side cover and doesn’t tear.
Page 24
I
I
I
III
III
.36
.36
III
III
.37
.37
2-shoe clutch assembly.
Adjust springs from 19 - 21mm.
Photo of kickstarter mechanism and spring.
Note 2 dowels in case.
Spring
installed
length
Diagram of two shoe clutch assembly.
III
III
.38
.38
adjust to
19 - 21mm
