Service manual

Page 63 of 151

8-2 Maintenance Description

Operating Procedures

General Information

• Drive face, clutch outer, and driven pulley can be serviced while

still installed.

• Drive belt and drive pulley must be free of grease.

V-BELT SYSTEM SPECIFICATIONS

Torque values

Drive face nut: 8.5-10.5kgf-m / 61-76 lbf-ft

Clutch outer nut: 5.0-6.0kgf-m / 36-43 lbf-ft

Drive plate nut: 5.0-6.0kgf-m / 36-43 lbf-ft

8-3 Troubleshooting

Engine starts but ATV does not move

1. Worn drive belt

2. Worn drive face

3. Worn or damaged clutch weight

4. Broken driven pulley

Sputter or misfire when driving

1. Broken clutch weight

2. Worn clutch weight

Item Standard value (mm) Limit (mm)

Driving belt width 24.000 22.500

OD of movable drive face boss 29.946~29.980 29.926

ID of movable drive face 30.000~30.040 30.060

OD of weight roller 19.500~20.000 19.000

ID of clutch outer 144.850~145.150 145.450

Thickness of clutch weight 6.000 3.000

Free length of driven pulley spring 102.400 97.400

OD of driven pulley boss 40.950~40.990 40.930

ID of driven face 41.000~41.050 41.070

Weight of weight roller 17.700~18.300 g 17.200 g

Special Service Tools

Clutch spring compressor: SYM-2301000

Inner bearing puller: SYM-6204002

Clutch nut wrench 39 x 41 mm: SYM-9020200

Universal holder: SYM-2210100

Bearing driver: SYM-9100100

Insufficient horsepower or poor high

speed performance

1. Worn drive belt

2. Insufficient spring force of driven pulley

3. Worn roller

4. Driven pulley malfunctioning