Filed Under (Harley Davidson) by admin on 11-02-2011
CLUTCH CABLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery or main fuse following the instructions in the appropriate Service manual. 2. When performing cable disassembly procedures, make careful notes as to the existing cable routing and existing cable strap locations. New straps can be installed in the same locations. 3. Remove the clutch cable following the instructions in the appropriate Service Manual. 4. If installing different handlebars, install them now (refer to the appropriate handlebar instruction sheet) and measure the change in distance that will be required from the end of the cable housing to the clutch lever. Install proper length clutch cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00448b) 5. Compare the additional required length to the cable provided in your kit. If the cable is more than two inches (50.8 mm) longer or more than one inch (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. CLUTCH CABLE INSTALLATION Sportster and Softail Models Do not over-tighten clutch cable threaded end fitting. Use recommended torque values. Damage to threaded fitting can lead to loss of transmission fluid, which could result in loss of control and death or serious injury. (00449c) -J04568
NOTE Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty. 1. See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing the O-ring onto the threaded portion of the clutch cable end. 2. Install the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). 3. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet. FLTR Models with Fairing Lowers 1. See Figure 1. Carefully twist the clutch cable around the coiled opening in the clutch cable guide (2) with the eyelet toward the left handlebar. 2. Route the clutch cable assembly down from the clutch cable clamp while crossing to the right side of the vehicle. Run the cable between the inboard side of the right frame downtube and the outboard side of the voltage regulator. 3. The clutch cable clamp, mounted on the engine guard, has two fingers, an upper and a lower. Feed the cable assembly under one finger and over the other. 4. Finish the installation of the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). NOTE See Figure 2. Adjust the clutch cable clamp to 2.25 ± 0.25 in. (57.15 ± 6.35 mm) as measured from the inside lower left fairing mount to the clutch cable clamp. 5. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet.
Filed Under (Harley Davidson) by admin on 21-03-2011
REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame
Filed Under (Honda) by admin on 23-04-2011
Refer to the 2008 CBR1000RR Service Manual for specific removal instructions. While completing this procedure, be careful not to damage the covers, cowls, or any other components. 1. Remove the air intake cover (page 3-8). 2. Remove the upper inner cover (page 3-9). 3. Remove the lower cowl (page 3-9). 4. Remove the right middle cowl (page 3-10). 5. Remove the right crankcase cover (page 10-5). Clutch Removal (page 10-7) 6. Remove the starter idle gear and shaft. 7. Remove the snap ring and stopper ring. 8. Remove the clutch lifter piece and plate. 9. Unstake the clutch center lock nut. Be careful not to damage the mainshaft threads. 10. Hold the pressure plate with the special tool. You must use the special tool (Clutch Holder, T/N 070MB-MFLA100) when removing the lock nut. Using an impact wrench will damage the main shaft threads. Clutch Holder: 070MB-MFLA100 (autoshipped in May 2008) 11. Remove the clutch center lock nut and washer and discard the lock nut as shown on top of page 3 12. Remove the clutch spring holder, spring seat, and two clutch springs. 13. Remove the spring seat. 14. Remove the following: • Pressure plate
• Spring seat • Judder spring • Clutch disc A • Clutch plate A • Seven clutch discs B • Clutch disc C Clutch center NOTE: Do not remove the clutch outer. New Clutch Installation (page 10-20) NOTE: The new clutch disc assembly has a dif- ferent order of plates than the illustration shown in the Service Manual. Keep note of this when repairing updated units.
15. Install the new clutch disc assembly with- out removing the setting bolts. Rotate the main shaft to align the clutch disc assem- bly with the main shaft spline. 16. Slightly loosen the setting bolts. 17. Rotate clutch disc C to align its tabs into clutch outer shallow slots, then fully install the clutch disc assembly. 18. Remove and discard the setting bolts. 19. Install the spring seat
Filed Under (Harley Davidson) by admin on 24-11-2010
REAK-IN PERIOD The ProStart clutch requires a short break-in period. During the break-in period, the ProStart should not be operated at steady engine speeds above 3000 RPMs for more than 10 minutes. Breaking-in the ProStart clutch equires start and stop cycles. Riding the ProStart clutch in stop-and-go city traffic for one hour will provide sufficient break-in. If you would like to accelerate the break-in period, find an empty parking lot with ample room and no other traffic. From a stop, bring the motorcycle to 20 miles per hour and then back to a stop. Repeat this process at least 20 times. MAINTENANCE Proper maintenance is important to ensure the longevity of the Rekluse ProStart clutch and the rest of the stock clutch components in your Harley- Davidson Motorcycle. Refer to your owner’s manual for proper primary chaincase oil levels and oil type. Rekluse recommends the use of Harley- Davidson Primary Chaincase lubricant with the Rekluse ProStart clutch. Do not use oils designed for use as automotive engine oil in your Primary Chaincase. If Harley-Davidson Primary Chaincase lubricant is not readily available, a premium-quality Diesel engine oil, such as Shell Rotella T, that does not contain friction modifiers may be substituted. Inspection and adjustment of the Rekluse ProStart clutch should only be performed by a service center trained in Harley-Davidson and Rekluse ProStart repair and maintenance. The Rekluse ProStart clutch should be inspected for adjustment after 1,000 miles of operation. Thereafter, inspection for adjustment should be performed at 5,000 mile intervals
Filed Under (Kawasaki) by admin on 25-10-2010
1. Remove the key from the ignition switch. Loosen the vent hose on the cover. Remove the clutch cover bolts (10mm socket) and take the clutch cover off. You will need to unplug the wires from the electric actuator and small sensor in the center of the clutch cover to totally remove the cover. To unplug the wires from the sensors, follow the wires to the connections under the plastic side panel and unplug at that location. 2. Remove the primary clutch bolt (19mm socket). This is a left threaded bolt. Insert clutch puller by hand (right hand threads) and tighten until clutch pops off the shaft. This tool is available from EPI, part number PCP-10. Loosen the secondary clutch nut (27mm socket) and remove both clutches at the same time. When you slide the secondary clutch of the machine there are four metal roller pins inside the center shaft of the secondary clutch. These will normally stay in place but if one does fall out refer to assembly instructions in step #6. 3. Disassemble the primary clutch by removing the eight bolts on the cover plate (10mm socket) and remove the spring. Remove one nut (10mm) on the bolt that holds the weight in place, slide the pin out of the clutch and remove the weight. Install EPI weight making sure the tip of the weight is resting on the inside ledge of the clutch. Slide bolt through the holes in the clutch and the weight and install the nut. Repeat this step for the other three weights. NOTE: If your kit has two different gram weights, for example two 54 and two 56 weights, be sure to place them directly across from each other (or every other one). This keeps the clutch in balance . 4. Install the EPI spring and bolt the clutch cover back on using a criss-cross pattern to tighten down the cover. There is a mark on the cover plate and the spider usually in the form of a dot or arrow in the casting. These are alignment marks and must line up when the clutch is assembled. 5. EPI recommends cleaning your clutches when you have them off your machine. Use a clean rag or towel with contact or brake cleaner that does not leave any oily film. Clean all parts of the clutch except for the clutch bushings. Solvent can damage your bushings; just use a dry rag to clean them