9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM 9 DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION ...........................................................9-2 TROUBLESHOOTING .................................................................9-2 LEFT CRANKCASE COVER ........................................................9-3 DRIVE PULLEY ..........................................................................9-3 9 CLUTCH/DRIVEN PULLEY.........................................................
9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM 5.5kg-m 5.5kg-m 5.
9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed in the frame. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. SPECIFICATIONS Item Movable drive face bushing I.D. Drive face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D.
MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS LEFT CRANKCASE COVER Air Tube Band REMOVAL Loosen the drive belt air tube band screw. Screw Remove the left crankcase cover bolts and left crankcase cover. Remove the gasket and dowel pins. Left Crankcase Cover Bolts DRIVE PULLEY Drive Pulley Face Nut REMOVAL Hold the drive pulley using an universal holder and remove the drive face nut and starting ratchet. Remove the drive pulley face.
9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 17.0mm replace if below ＊ Use specified genuine parts for replacement. Remove the movable drive face assembly. Remove the drive pulley collar. Drive Pulley Collar Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate. Weight Rollers Remove the weight rollers.
9. DRIVE AND DRIVEN PULLEYS INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 20.42mm replace if below. Measure the movable drive face bushing I.D. Service Limit: 27.06mm replace if over Check the drive pulley bushing for wear or damage. Measure the O.D. of the drive pulley bushing sliding surface. Service Limit: 26.
9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM ASSEMBLY Install the weight rollers into the movable drive face. Weight Roller Ramp Plate Install the ramp plate.
MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Insert the drive pulley collar into the movable drive face. Drive Pulley Collar INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D. Service Limit: 130.
. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor E027 Set the clutch spring compressor in a vise and remove the clutch drive plate nut. Lock Nut Wrench Loosen the clutch spring compressor and disassemble the clutch/driven pulley assembly. Remove the seal collar. Check the driven face for wear or damage.
9. DRIVE AND DRIVEN PULLEYS Remove the oil seal from the movable driven face. INSPECTION Measure the driven face spring free length. Service Limit: 83.2mm replace if below Check the driven face for wear or damage. Measure the driven face O.D. Service Limit: 33.94mm replace if below Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.
9. DRIVE AND DRIVEN PULLEYS MX’er SYSTEM Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. ＊ Discard the removed bearing and replace with a new one. Remove the snap ring and drive the outer bearing out of the driven face. Outer Bearing ＊ Discard the removed bearing and replace with a new one. Apply grease to the outer bearing. Drive a new outer bearing into the driven face with the sealed end facing up.
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9. DRIVE AND DRIVEN PULLEYS Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips. MX’er SYSTEM Retainer Plate Drive Plate Clutch Weights/Shoes Springs Circlip Movable Driven Face CLUTCH/DRIVEN PULLEY ASS EMBLY Clean the driven pulley faces and remove any grease from them. Install the oil seal onto the moveable driven face.
MX’er SYSTEM 9. DRIVE AND DRIVEN PULLEYS Clutch Spring Compressor Compress the clutch spring compressor and install the drive plate nut. Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque. Torque: 5.0_ 6.0kgf-m ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor E027 Lock Nut Wrench Clutch INSTALLATION Install the clutch/driven pulley onto the drive shaft. ＊ Keep grease off the drive shaft.
9. DRIVE AND DRIVEN PULLEYS Install the left crankcase cover and tighten the cover bolts diagonally. Connect the drive belt air tube and tighten the band screw.
