L
Before inspecting, cleaning or servicing the machine, shutoff engine, wait for all moving parts to
come to a complete stop, disconnect spark plug wire and move wire away from spark plug. J
Removethe key from the keyswitch on units soequipped. J
Failure tofollow these instructionscan result in serious personal injury or property damage.
Incorrectcable adjustmentcould cause
thewheels and tines to rotateunexpect-
edly. Follow adjustment procedures
carefully. Failure to do so could result
inpersonalinjury or propertydamage.
CheckingForwardBeltTension
1. Beforechecking, shut off engine, allow
theengine and muffler to cool down, dis-
connectthe spark plug wire, removethe
ignition key on electric start models.
2.The coiled part of the forward clutch
spring(E, Figure5-10) measures2" in
lengthwhen the Forward ClutchControl
leversare not pulledup. Pull either
ForwardClutch Control Lever up against
the handlebarand measure the length of
thecoil on the forward clutch spring.
Tension iscorrect if the length of the
extendedcoil is 2-1/2" (see Figure5-11).
Theforward clutch control cable needs
adjustment if the extended length of the
coilis not2-1/2". SeeAdjusting the
ForwardClutch Beltfor a procedure.
Adjustingthe ForwardClutchCable
Dothis procedure if the forward clutch
springmeasurement is notcorrect (see
CheckingForward Belt Tension).
1. Beforeadjusting thebelt, shut off
engine,allow the engine and muffler to
cooldown, disconnectthe spark plug
wire, and remove the ignition keyon elec-
tric start models.
ATension.
Figure5-12: Moveforward clutch cable
adjusterdown for more belt tension,
2. Belt adjustments are done with the
forward clutch cable adjuster (F,Figure 5-
10). Usetwo 1/2",open-end wrenches to
loosenthe two jam nuts (A, Figure 5-12)
afew turns.
3. Movecable adjuster (B, Figure 5-12)
downwardfor more belttension (see
Figure5-12).
4. Handtighten thejam nutsand pullthe
ForwardClutch Control leversupagainst
thehandlebar. Measurethe spring coil
(Figure5-11). The extendedlength of the
coilshould be2-1/2". Repeatthis proce-
dureuntil theextended spring length is
correct.
5.Tighten bothjam nutssecurely.
CheckingandAdjustingReverse
ClutchBeltTension
CheckingReverseClutchBeltTension
Thereverseclutch belt (D, Figure5-9)
needsadjustment if the belt slips in
reverseor if there is no reverse. See
Adjusting ReverseClutch Belt below.
AdjustingReverseClutchBelt
1. Beforeadjusting thebelt, shutoff
engine,allow the engine and muffler to
cooldown, disconnectthe spark plug
wire,and remove the ignition key on elec-
tric start models.
Figure5-13:Beltcover.
2. Removethe two nuts (C,Figure5-13)
andremove the belt cover.
3. Reversebelt tension adjustments are
donewith the reverse clutch cable
adjusterlocated on the leftside of the
machinenear the engine (D, Figure 5-14).
Usetwo 1/2"open-endwrenches to
loosenthe two adjusterjam nuts (E)a few
turns.
Figure5-14: Reverse clutchcable adjuster.
Left-sideview withbeltcover removed.
4. Movethe cable adjuster (D, Figure
5-14) awayfrom the pulleys to increase
belttension.
5. Tighten both jam nutssecurely.
6. Reinstallthe belt cover.
7. Move the unit toan open area and test
thereverse operation. Repeatthis proce-
dure if the unit does not respondwhen
thereverse clutch is engaged.
FORWARD CLUTCH BELTREMOVAL
AND REPLACEMENT
Theforward clutch belt (K,Figure 5-15)
engagesthe engine pulley (I) and the
transmission pulley (J) when either
ForwardClutch Control Lever is pulled up
againstthe handlebar. This tightens the
forward clutch cable (G) which causesthe
forward clutch idlerpulley (H)to apply
pressureto the forward clutch belt. This
causesthe pulleysto turn for Forward
movement.
Figure5-15: Forwardclutchcontrol
assembly.