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ADJUSTMENT
Check clutch adjustment:
At the 500 mile (800 km) service interval.
At every 5000 mile (8000 km) service interval thereafter.
If clutch slips under load or drags when released, first check
control cable adjustment. If cable adjustment is within specifi-
cations, adjust clutch mechanism as described below.
When necessary, lubricate cable with LUBIT-8 TUFOIL
CHAIN AND CABLE LUBE (Part No. HD-94968-85TV).
1.
Raise rear of vehicle off the floor using
SUPPORT STAND (Part No.
2.
See
Figure 1-18.
Slide rubber boot (1) upward to expose
adjuster mechanism. Loosen jam nut (3) from adjuster
(4). Turn adjuster to shorten cable housing until there is a
large amount of freeplay at clutch hand lever.
3.
See
Figure 1-19.
Remove TORX screws with washers (1)
from clutch inspection cover (2). Remove clutch inspec-
tion cover from primary cover, but leave Quad ring (3) in
place.
4.
Remove spring (4) and adjusting screw lockplate (5).
Turn adjusting screw counterclockwise until it lightly bot-
toms.
5.
Turn clutch adjusting screw (6) clockwise 1/4 turn. Install
lockplate (5) and spring (4) on adjusting screw flats. If
hex on lockplate does not align with recess in outer ramp,
rotate adjusting screw clockwise until it aligns.
6.
Squeeze clutch lever to maximum limit three times to set
ball and ramp mechanism. Pull outer cable conduit and at
the same time adjust cable adjuster to provide 1/16-1/8 in.
(1.6-3.2 mm) freeplay at hand lever. Adjust as follows.
a.
See
Figure 1-20.
Pull clutch cable ferrule (end of
cable housing) away from clutch hand lever bracket.
Gap between ferrule and bracket should be 1/16-1/8
in. (1.6-3.2 mm).
b.
See
Figure 1-18.
Adjust freeplay by turning cable
adjuster (4).
c.
Tighten jam nut (3) against adjuster (4).
d.
Slide boot (1) over cable adjuster mechanism.
7.
Change or add transmission fluid if necessary.
8.
Install clutch inspection cover (2). Tighten TORX screws
with washers (1) in a crosswise pattern to 7-9 ft-lbs (9-
12 Nm).
9.
Check clutch cable freeplay. See Step 6 above.
1-20
REAR WHEEL
B-41174).
www.PlanDeGraissage.org
5594
3
®
1.
Rubber boot
2.
Cable end
Figure 1-18. Clutch Cable Adjuster Mechanism
b0152x6x
2
1
5
4
1.
Torx screw with washer
2.
Clutch inspection cover
3.
Quad ring
Figure 1-19. Clutch Release Mechanism
5595
Adjust for 1/16-1/8 in. (1.6-3.2 mm)
gap between ferrule and bracket
Figure 1-20. Adjusting Clutch Freeplay
1
2
4
3.
Jam nut
4.
Adjuster
6
3
4.
Spring
5.
Lockplate
6.
Adjusting screw
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