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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.
Remove the keyfrom the keyswitch on unitsso equipped.
Failure to follow these instructionscan result in serious personal injury or property damage.
Incorrectcable adjustment could cause
the wheels andtines to rotate unexpect-
edly. Follow adjustment procedures
carefully. Failure to do so could result
in personalinjuryorpropertydamage.
CheckingForward Belt Tension
1. Beforechecking, shut off engine, allow
the engine and muffler to cool down, dis-
connect the spark plug wire, removethe
ignition keyon electricstart models.
2. Thecoiled part of the forward clutch
spring (E, Figure5-10) measures2" in
lengthwhen the Forward Clutch Control
leversare not pulled up. Pull either
ForwardClutch Control Lever up against
the handlebar and measurethe length of
the coil on the forward clutch spring.
Tension is correct if the length of the
extended coil is 2-1/2" (see Figure5-11).
Theforward clutch control cableneeds
adjustment if the extendedlength of the
coil is not 2-1/2". SeeAdjusting the
Forward ClutchBeltfor a procedure.
Adjustingthe Forward ClutchCable
Dothis procedure if theforward clutch
spring measurement is not correct (see
CheckingForward Belt Tension).
1. Beforeadjusting the belt,shut off
engine, allowthe engine and muffler to
cool down, disconnect the spark plug
wire, and remove the ignition key on elec-
tric start models.
,
Tension.
Figure5-12: Moveforwardclutchcable
adjusterdownformorebelttension.
2. Beltadjustments aredone with the
forward clutch cableadjuster (F,Figure5-
10). Usetwo 1/2",open-end wrenchesto
loosenthetwo jam nuts (A, Figure5-12)
a few turns.
3. Movecable adjuster (B, Figure5-12)
downward for more belt tension (see
Figure5-12).
4. Handtighten thejam nuts and pull the
ForwardClutch Control leversup against
the handlebar. Measurethe spring coil
(Figure5-11). The extendedlength of the
coil should be2-1/2". Repeatthis proce-
dure until the extendedspring length is
correct.
5. Tighten bothjam nuts securely.
CheckingandAdjustingReverse
ClutchBeltTension
CheckingReverseClutchBelt Tension
The reverseclutch belt (D, Figure5-9)
needsadjustment if the belt slips in
reverseor if there is no reverse. See
Adjusting ReverseClutchBelt below.
AdjustingReverseClutchBelt
1. Beforeadjusting the belt,shut off
engine,allow the engine and muffler to
cool down, disconnectthe spark plug
wire, and removethe ignition key on elec-
tric start models.
I
Figure5-13: Belt cover.
2. Removethetwo nuts (C, Figure5-13)
and removethe belt cover.
3. Reversebelttension adjustmentsare
donewith the reverseclutch cable
adjuster located on the left side of the
machine nearthe engine (D, Figure 5-14).
Usetwo 1/2" open-endwrenchesto
loosenthetwo adjuster jam nuts (E) afew
turns.
Figure5-14: Reverse clutchcable adjuster.
Left-side viewwith beltcoverremoved.
4. Move the cableadjuster (D, Figure
5-14) awayfrom the pulleys to increase
belt tension.
5. Tighten both jam nuts securely.
6. Reinstallthe belt cover.
7. Move the unit to an openareaand test
the reverseoperation. Repeatthis proce-
dure if the unit does not respondwhen
the reverseclutch is engaged.
FORWARD CLUTCH BELTREMOVAL
AND REPLACEMENT
Theforward clutch belt (K, Figure5-15)
engagesthe engine pulley (I) and the
transmission pulley (J) wheneither
Forward ClutchControl Leveris pulled up
againstthe handlebar. This tightens the
forward clutch cable (G)which causesthe
forward clutch idler pulley (H) to apply
pressureto the forward clutch belt. This
causesthe pulleysto turn for Forward
movement.
Figure5-15: Forwardclutchcontrol
assembly.