Clutch Release Mechanism - Buell 2003XB9S Service Manual

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CLUTCH RELEASE MECHANISM

DISASSEMBLY
NOTE
For clutch adjustment procedure, See
1. Remove seat. See 2.41 SEAT.
11 1
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.
2. Disconnect negative battery cable.
3. Slide rubber boot on clutch cable adjuster upward to
expose adjuster mechanism. Loosen jam nut from
adjuster. Turn adjuster to shorten cable housing until
there is a large amount of freeplay at clutch hand lever.
See 1.9 CLUTCH.
4. See Figure 6-9. Remove three TORX screws with wash-
ers and clutch inspection cover.
5. Slide spring (4) with attached screw lockplate (5) from
flats of adjusting screw.
b1057x6x
1. TORX screw with washers (3)
2. Clutch inspection cover
3. Clutch cover gasket
4. Spring
5. Lockplate
6. Nut
1.9 CLUTCH.
WARNING
11
Figure 6-9. Clutch Release Mechanism
6. Turn adjusting screw clockwise to release ramp and cou-
pling mechanism (7). As the adjusting screw is turned,
ramp assembly moves forward. Unscrew nut (6) from
end of adjusting screw.
7. Remove hook of ramp from cable end coupling (10).
Remove cable end from slot in coupling.
8. Remove and discard retaining ring from ramp assembly
to separate inner and outer halves. Remove three balls
from ramp sockets.
CLEANING AND INSPECTION
1. Thoroughly clean all parts in cleaning solvent.
2. See Figure 6-9. Inspect three balls of release mecha-
nism 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 and outer 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.
9
8
7
6
5
10
7. Ramp assembly
8. Adjusting screw assembly
9. Primary cover
10. Coupling
11. Drain plug and o-ring
2003 Buell XB9S: Drive/Transmission
6.3
4
3
2
1
1.9
6-7