Friction Disc Replacement

6	11	5	1	2	3	4		6
							5

	10		6			9	8	7


1. Hex Shaft				7. Bearing Cap
2. Friction Disc					Screws
3. Hex Bolts & Nuts				8. Bearing Cap/
4. Shift Carrier					Bushing
5. Roll Pins				9. Clutch Fork
6. Washers				10.Large Gear
				11.Pinion Gear
			Figure 22					OS2002

Remove Friction Disc

(Figure 22):

1.Shut off engine, remove key, disconnect spark plug wire and allow unit to cool completely.

CAUTION: Before tipping unit, remove enough fuel so that no spills occur.

2.Tip the unit up onto front housing on a level surface.

3.Remove lockpins from wheel axles and remove wheels.

4.Remove two (2) bolts from top of bottom cover.

5.Loosen two (2) bottom screws and slide cover off.

6.Remove hair pin and washer from shift rod. Disconnect shift rod from speed selector arm. Reinstall hairpin and washer on rod.

7.Remove four (4) nuts from bearing cap on left side of unit.

8.Reinstall one nut to keep the inside bearing cap in place.

9.Remove bearing cap/bushing and washer from right side of unit.

10.Reinstall nuts on screws through side frame to keep screws in place.

11.Carefully tap two (2) roll pins out of center and right end of shaft.

12.Slide friction disc assembly and hex shaft to the right until the left end of shaft is clear of left bearing. Tap lightly if necessary, to loosen. The shaft slides out of the small pinion gear and washer.

13.Carefully lift shaft and friction disc out of unit. As you remove the assembly, the washers between the bearing and sliding forks will be loose. Do not lose the washers.

Replace Friction Disc

1.Remove three (3) hex bolts and nuts holding friction disc to shift carrier.

2.Remove the old friction disc. Put the new friction disc in place, flat side to the shift carrier.

3.Reinstall the three (3) bolts and nuts into the new friction disc and hub. Torque to 5-6 lbf-ft (6.8 to 8.13 N•m).

Reinstall Friction Disc

1.Reinstall the shift carrier, the small pinion gear and washer onto the hex shaft. The washer goes between the bearing and the pinion gear.

2.Slide the shaft and attached parts into the frame, through the right side hole first, then the left. Pinion gear must mesh with the large gear.

3.Reinstall the bearing and outside bearing cap on the left side of the frame.

4.On the right side of the frame, place the washer on the end of the shaft.

5.Reinstall the bearing cap/bushing on the right side of frame.

6.Reinstall the flange bearing and washers into the shift forks. Be sure the washers are inside the forks.

7.Reinstall roll pins in shaft. Be sure pins are centered in shaft.

8.Reinstall shift rod with hairpin and washer.

9.Reinstall tires with lockpins.

10.Install bottom cover.

11.Set unit upright.

12.Replace spark plug wire on spark plug.

GB - 26

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