Service manual
c
CAUTION!
Always
disconnect
spark
plug
wires
before
working on
the
engine
or
drive
elements.
•
Release
the chain
cover
straps
and
remove
the
chain
cover
tou.
•
Loosen
the
bolts
(1,
figure
5)
on both
cam
up-
rights
(2)
and
rotate
the
cam
and
shaft
(3)
as
re-
quired
to
loosen
the chain tension. During
reassem-
bly, apply 30 foot-pounds
torque
to the bolt (1).
• Remove the
cotter
pin,
slotted
nut and
washer
securing
the top
sprocket
to the
driven
clutch shaft.
Rell10ve
the
top
sprocket
and chain
together.
During
reassembly,
add No.2 Lithium
bearing
grease
to
the
chain
case.
•
Reassembly
is
the
reverse
of
removal.
Perform
drive
chain
adjustment
procedures.
Drive Chain
Adjustment
A
properly
adjusted
drive
chain (figure
5)
should
have a
1/8-
to
1/
4-inch
slack.
Check and
adjust
chain
as
follows:
•
Release
the
chain
cover
straps
and
remove
the
chain
cover.
• Check chain
for
proper
slack.
If
adjustment
is
required,
loosen
the
screws
(1)
securing
the
cam
blocks
(2)
on
each
side.
• Rotate the
cam
(3)
counterclockwiseto
tighten
or
until the chain
is
properly
tensioned. Hold the
cam
in
this
position
while tightening the
cam
block
screws
(1)
on
each
side.
Be
certain
the
lateral
alignment
between the
drive
clutch and the
driven
clutch
(4)
is
maintained while the
cam
block
screws
are
tightened.
• Recheck chain
tension
before
replacing
the chain
case
cover.
To
Remove
Variable-
Speed
Drive Belt
• Remove the
drive
chain.
Refer
to
paragraph
To
Remove
Drive
Chain.
• Remove the clutch
guard
assembly.
• Loosen
the
locknut (9,
figure
5)
and
serrated
washer
(10)
securing
the
clutch
rod
tensioner
(11)
7
~I
SERVICE
AND
REPAIR
leSaaij
to the main
frame.
During
reassembly,
apply 10
foot-pounds
torque
tel>
the locknut (9).
•
Push
tlte
driven
clutch
toward
the
drive
clutch
sufficiently to allow
removal
of the
variable-speed
drive
belt
from
the
drive
clutch.
• Remove the locknuts (7,
figure
4)
and
washers
securing
the
bearing
clamps
(8)
and
remove
the
bearing
clamps.
During
reassembly,
apply 5 foot-
pounds
torque
to the locknuts (7).
• Lift
the
driven
clutch
(9)
and
drive
belt
clear
of the
brake
assembly
(10)
and away
from
the chain
case.
• Remove the
variable-speed
drive
belt.
NOTE:
Variable
-s
peed
drive
belt
installation
pro-
cedures
are
the
reverse
of
removal
except
that
the
belt
must
first
be
placed
around the
driven
clutch
and then around the
drive
clutch.
After
installation,
perform
the
drive
chain
adjustment,
variable-speed
belt
adjustment
and the
drive
clutch
alignment
procedures.
Variable
-S
peed
Drive Belt
Adjustment
Proper
tension
for
a new
drive
belt
should be
ob-
tained
when the clutch
centers
are
set
apprOximately
10-3/4
inches
apart
(see
figure
6).
Proper
tension
for
a
drive
belt
that
has
been
used
is
obtained when
opposite
sides
of
the
belt
can
be squeezed, between
the
drive
clutches
to the following dimensions:
Mark
IV
Mark
V
2-3/4
to
3-1/4
inches
4 to
4-1/2
inches
The
measurement
must
be
taken
between the top
and bottom outside
surfaces
of the
belt
a..T1d
as
cl
ose
to the
drive
clutch
flanges
as
possible.
Be
certain
the
driven
clutch does not open when
belt
is
squeezed.
IMPORTANT:
Do
not
use
antislip
belt
dreSSing.
Use
of
belt
dreSSing will void the
owner's
guar-
antee
as
belt
slippage
is
a
safety
feature
which
prevents
overstressing
the
drive-system
compo-
nents.
• To
adjust
drive
belt
tension,
loosen
the locknut
(9,
figure
5)
securing
the
clutch
rod
tensioner
to
the
main
frame
assembly.
NOTE:
If
the
drive
belt
is
wearing
unevenly,
check
drive
belt
alignment
as
described
in
Drive
Clutch
Alignment
procedures.