Club Car 2007 Carryall 295 Maintenance And Service Manual page 424

13B
HONDA GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
1.2. Install new rollers and secure the rollers with pins.
2. Inspect the rollers (10) and weights (11). There should be no noticeable wear. If the rollers or weights are
worn, scratched, or damaged, replace them.
2.1. Remove the bolts (12) and flex locknuts (13) that secure the rollers (10) to the spider (6) and the
weights (11) to the moveable sheave (14).
2.2. Install new rollers and weights with bolts and flex locknuts.
Drive Clutch Assembly
NOTE: The drive clutch components are marked with an X to assist in correct reassembly. It is important
to note the location of the X on the components and be sure to align the X's when assembling the
drive clutch.
1. Place the moveable sheave (14) and spider (6) onto the fixed sheave (15). Note the location of the X so
the remaining components with an X can be aligned.
2. Use a spider removal tool (CCI P/N 102607501) to tighten the moveable sheave and spider to 225 ft-lb
(305 N·m).
3. Install the spring (5) onto the shaft.
4. Install the cover (4) onto the shaft.
5. Align the plate that has holes in the cover with arrows on the same side. Pull the moveable sheave
upward and start threading the bolts with washers into holes. See following NOTE.
NOTE: Keep the cover as square to the post as possible to minimize wear between the post and cover.
6. Use a crisscross pattern to continue tightening the hardware.
7. Tighten the bolts to 120 in-lb (14 N·m).
Drive Clutch Installation
1. Turn the key switch OFF and remove the key. Set the park brake. Place the Forward/Reverse handle in
NEUTRAL.
2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-2.
3. Disconnect the spark plug wires. See WARNING "To avoid unintentionally starting..." in General
Warning, Section 1, Page 1-2.
4. Place the drive clutch assembly on the crankshaft taper.
5. Install the mounting washer and retaining bolt. Tighten the hardware to 39 ft-lb (53 N·m).
6. Install the drive belt as instructed. See Drive Belt Installation on page 13b-31.
7. Install the clutch outer cover and tighten the bolts to 72 in-lb (8.0 N·m).
8. Secure the top air filter hose (outlet) to the filter canister. See following NOTE.
NOTE: Ensure the hose contacts the canister and the clamp is installed tightly between the port bead and
canister.
9. Connect the spark plug wires.
10. Connect the battery cables, positive (+) cable first, and tighten the hardware to 144 in-lb (16 N·m). Coat
terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
11. Drive the vehicle and check for proper operation.
Page 13b-34 2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
Clutches