Two shoe clutch
- Refer to three shoe clutch section for removal and
replacement of 2 shoe clutch. The engagement RPM of the two shoe clutch
can be adjusted by loosening or tightening the two nuts on the clutch assem-
bly. The use of the optional HD clutch springs is recommended.
The stan-
dard duty springs are made of .XXX” wire, while the HD springs are
made of .XXX” wire.
The springs can be adjusted from an installed length
of 19 to 21mm to vary the clutch engagement speed. Make sure both springs
are set to the same length. Measure length of spring between retaining wash-
ers to check installed length. See photo III-38. Tightening the springs will
raise the engagement RPM of the clutch assembly, resulting in harder more
powerful starts. Loosening the springs will decrease the engagement RPM
resulting in slower and less powerfull starts. If the motor seems to bog and
has trouble getting the bike moving, decrease the spring length and install the
HD springs if not so equipped. As the rider becomes more aggressive, a
switch to a 3-shoe clutch may be desirable.
Kickstarter -
To remove kickstarter lever, use a
6mm
allen wrench to
remove attaching bolt. Wiggle kickstarter lever and pull off shaft. If lever is
difficult to remove, spray some penetrating oil on splines and gently spread
slot with screwdriver to ease kickstarter lever off. To service kickstarter drive gear,
remove clutch cover from engine. Remove two
6mm
allen bolts and retaining plate.
Make note of proper spring position, then remove spring. The drive gear and shaft can
now be removed. See photo III-37. If seal is to be replaced, drive old seal out from
inside of case, and press new seal into place.
Bikes prior to 2002 had a weaker early style kickstarter drive gear and driven gear.
See photos III-39 & III-40. These parts can be upgraded, but due to the thicker drive
gear, the clutch cover case will need to be machined to match. A new driven gear and
clutch nut must be used with the new drive gear. A new clutch cover case with the
proper dimensions can be purchased rather than machining the old case. See illustra-
tion III-41 to determine if your case needs to be machined. The new kickerstarter gear
& shaft assembly is part number 144.131.001. You will also need a new driven gear
(144.110.001) and clutch nut (144.111.001). Do not use the old style driven gear and
clutch nut or the drive gear will bind on the driven gear and the kickstart lever will not return to rest position, causing damage. If
case is to be machined, have work done by a competent machinist. It is important that the proper clearances be obtained and that the
machined surface is parallel to the case mounting surface.
Reassembly -
Begin by lubricating kickstarter shaft, seal and bore with grease. Install kickstarter shaft from inside of case, being
careful not to damage the seal. Install the kickstarter spring and retainer plate, using blue threadlocker on bolts. Using a 6mm allen
wrench, torque bolts to
XX ft/lbs
. See photo III-37. Check spring for proper placement and operate lever to check for binding or
interference.
Install new style driven gear and clutch nut, see beginning of this section for removal and installation procedure.
Page 25
I
I
I
Dimensions of clutch cover case for early and late style kickstarter gears.
2
mm
19.2
mm
21.2
mm
25.5
mm
27.5
mm
measurements
shown
+
⁄
-
0.1
mm
early style
late style
clutch cover
kickstarter shaft bore
III
III
.41
.41
New and old style kickstarter drive gears.
New and old style kickstarter driven gears.
New style
New style
Old style
Old style
III
III
.39
.39
III
III
.40
.40
clutch cover side view
