two semi circular cutouts fits into the
clutch housing slot with the two
marks. See
Figure 15
. This slot (A,
Figure 25
) is cut down to the bottom
of the clutch housing.
9. Install the first friction disc (
Figure 26
) so the
tab with the two semi-circular cutouts fit into the
marked slot on the clutch housing.
10. Install the first clutch plate (
Figure 27
), then
install the next friction disc. Continue alternately
installing a clutch plate, then a friction disc, until all
plates and discs are installed. The last item installed
should be friction disc.
11. Make sure the marked tab on each friction disc
sits in the marked slots on the clutch housing as
shown in
Figure 15
. If necessary, remove the fric-
tion discs and clutch plates. Reinstall them cor-
rectly.
12. Lubricate pushrod No. 2 with lithium soap
grease and install it into the mainshaft so its round
end faces out (
Figure 14
).
13. Lubricate pushrod No. 1 with lithium-soap
grease and install it into the mainshaft (
Figure 13
).
14. Install the release bearing (
Figure 12
) onto
pushrod No. 1, then install the washer (
Figure 11
).
15. Install the pressure plate (B,
Figure 10
) into
place so its splines engage those of the clutch boss.
16. Install the spring seat (A,
Figure 10
) onto the
pressure plate and set the clutch spring (
Figure 9
)
into the spring seat. Make sure the convex side of
the spring faces out.
17. Install the spring plate (B,
Figure 8
) into place
and loosely install the clutch spring bolts (A). Ap-
ply a medium-strength threadlocking compound to
the threads of the bolts.
18. Evenly tighten the bolts in a crisscross pattern.
Torque the clutch spring bolts 8 N•m (71 in.-lb.).
19. Adjust the clutch lever free play as described in
Chapter Three.
Inspection
1. Clean all clutch parts in a petroleum-based sol-
vent, such as a commercial solvent or kerosene.
Thoroughly dry the parts with compressed air.
2. Inspect the friction discs as described below. If
any disc must be replaced, replace all the friction
discs as a set.
a. Check the friction material (A,
Figure 28
) for
excessive wear, cracks and other damage.
b. Inspect the friction disc tangs (B,
Figure 28
)
for surface damage. Pay particular attention
to the sides of the tangs where they slide
along the clutch housing slots. If these tangs
are not smooth, the clutch will not disengage
and engage correctly.
c. Measure the thickness of each friction disc
(
Figure 29
) at four places around the disc. If
any disc is worn to the service limit (
Table 1
),
replace all the friction discs as a set.
3. Inspect the clutch plates as follows:
CLUTCH AND PRIMARY DRIVE GEAR
175
6
26
27
28
