Clutch Release Mechanism - Buell 2002 X1 Handbook

HOME

CLUTCH RELEASE MECHANISM

NOTE
See 1.10 CLUTCH for clutch adjustment procedure.
DISASSEMBLY
1 1
WARNING WARNING
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
1. Disconnect negative battery cable from battery terminal.
2. 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 (1.6-3.2 mm). Adjust freeplay
by turning cable adjuster.
3. See Figure 6-10. Remove four TORX screws with wash-
ers (1) and clutch inspection cover (2).
4. Slide spring (3) with attached screw lockplate (4) from
flats of adjusting screw (12).
1. TORX Screw with Washer (4)
2. Clutch Inspection Cover
3. Spring
4. Lockplate
5. Wellnut
6. Outer Ramp
7. Ball (3)
8. O-Ring
9. Cable End Fitting
10. Clutch Cable End
11. Primary Cover
12. Clutch Adjusting Screw
13. Retaining Ring
14. Quad Ring
15. Inner Ramp
16. Coupling
6-8
9
2
4
1
Figure 6-10. Clutch Release Mechanism
5. Turn adjusting screw (12) clockwise to release ramp and
coupling mechanism. As the adjusting screw is turned,
ramp assembly moves forward. Unscrew nut (5) from
end of adjusting screw.
6. Remove hook of ramp from cable end coupling (16).
Remove cable end (10) from slot in coupling.
7. Remove and discard retaining ring (13) from ramp
assembly to separate inner and outer halves. Remove
three balls (7) from ramp sockets.
CLEANING AND INSPECTION
1. Thoroughly clean all parts in cleaning solvent.
2. See Figure 6-10. Inspect three balls (7) of release mech-
anism and ball socket surfaces of inner and outer ramps
for wear, pitting, surface breakdown and other damage.
Replace parts as necessary.
3. Check hub fit of inner (15) and outer (6) ramps. Replace
ramps if excessively worn.
4. Check clutch cable for frayed or worn ends. Replace
cable if damaged or worn.
5. Change or add transmission fluid if necessary. See
CLUTCH.
10
8
7
13
14
15
16
5
6
3
11
12
2002 Buell X1: Drive/Transmission
6.4
1.10
b0131a6x