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Beforeinspecting,cleaningor servicingthe machine, shutoff engine, wait for all movingparts to cometo
a complete stop, remove ignition key on electric start models, disconnectsparkplug wire and move wire I
away from sparkplug.
Fa ure to fo ow these nstructons can resu t n ser ous persona njury or propertydamage.
NOTE: Do not loosen the nuts more than
a few turns for each adjustment check.
3. Move cable adjuster (B, Figure 5-12)
downward for more belt tension.
4. Handtighten thejam nuts and pull the
Forward Clutch Control levers up against
the handlebar. Measure the spring coil
(Figure 5-11). The extended length of the
coil should be 2-1/2% Repeatthis proce-
dure until the extended spring length is
correct.
NOTE: A new belt is needed when thejam
nuts are adjusted close to the end of the
threadedadjuster.
5. Tighten bothjam nuts securely.
Checking and AdjustingReverse
Clutch Belt Tension
CheckingReverse ClutchBelt Tension
The reverse clutch belt (D, Figure5-9)
needsadjustment if the belt slips in
reverse or if there is no reverse. See
Adjusting ReverseClutch Belt below.
AdjustingReverse ClutchBelt
1. Before adjusting the belt, shut off
engine, allow the engine and muffler to
cool down, disconnect the spark plug
wire, and remove the ignition key on elec-
tric start models.
2. Removethe two flange Iocknuts (C,
Figure 5-13) and remove the belt cover.
Figure5-13: Beltcover.
3. Reversebelt tension adjustments are
done with the reverse clutch cable adjuster
located on the left side of the machine
near the engine (D, Figure 5-14). Use two
1/2" open-end wrenches to loosen the two
adjusterjam nuts (E) a few turns.
NOTE: Do not loosen the nuts more than
a few turns for each adjustment check.
Move cable
adjuster away
from pulleysto
increasereverse
belt tension.
Figure5-14: Reverse clutchcable adjuster.
Left-side view with belt coverremoved.
4. Move the cable adjuster (D, Figure
5-14) away from the pulleys to increase
belt tension.
NOTE: A new belt is neededwhen thejam
nuts are adjusted close to the end of the
threadedadjuster.
5. Tighten bothjam nuts securely.
6. Pull back on the ReverseClutch Control
knob and make sure that the reverse
clutch belt fully contacts the groove in the
engine pulley. Releaseknob and make
sure that the belt doesn't engagethe
reverse engine pulley (L, Figure5-14). If it
does, it may cause the unit to move in
reverse when the Wheel Gear Lever is
engaged. Adjust the cable for less tension
if this condition occurs. See Checking
and Adjusting Reverse Belt Tensionfor
more information.
7. Reinstallthe belt cover.
8. Move the unit to an open area and test
the reverse operation. Repeatthis proce-
dure if the unit does not respond when the
reverse clutch is engaged.
FORWARD CLUTCH BELT REMOVAL
AND REPLACEMENT
The forward clutch belt (K, Figure 5-15)
engagesthe engine pulley (I) and the
transmission pulley (J) when either
Forward Clutch Control Lever is pulled up
against the handlebar. Pulling the lever(s)
tightensthe forward clutch cable (G)
which causes theforward clutch idler
pulley (H) to apply tensionto theforward
clutch belt. This causesthe belt to trans-
fer power from the engine pulley to the
transmission pulley for Forward
movement.
Figure5-15: Forward clutchcontrol
assembly.
RemovingForwardClutch Belt
1. Stop engine, allow it to cool and dis-
connect spark plug wire before working
near belts= Also remove ignition key on
electric start models=
2. Remove the two nuts (C, Figure 5-13)
and remove the belt cover.
3. Move the reverse clutch belt (A, Figure
5-16) out of the way. Press on the reverse
idler pulley to create slack. Then slip the
bottom half of the belt completely off the
transmission pulley. Pull the bottom half
of the belt out of the housing and let it
hang outside the unit (B).
FigureS_16
4. On left-side of unit, disconnect the
forward clutch cablefrom the forward
clutch idler arm bracket (Figure 5-17).
Note the hole from which you disconnect
the cable. It is important to reconnect the
cable to the same hole.
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