Page J-4
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
Drive Clutch Installation
(Ref. Fig. 3)
Clean both the engine crankshaft and the drive clutch
bore. Slide the clutch onto the engine crankshaft and
rotate the clutch while lightly pushing the moveable
sheave in and out several times to seat the clutch with
the tapered crankshaft (Ref. Fig. 3).
Install the washer (3) and the large pilot washer (4) onto
the clutch bolt (2).
Apply thread sealant to the threads of the clutch bolt (2)
and install and tighten to the specified torque.
Driven Clutch Removal
Tool List
Qty.
Plastic fAced Hammer ................................................. 1
Clutch Puller, (p/n 608429) .......................................... 1
External Snap Ring Pliers............................................ 1
Wrench, 18 mm ........................................................... 1
Socket, 18 mm............................................................. 1
Impact Socket, 19 mm................................................. 1
Impact Wrench (air or electric) .................................... 1
Ratchet ........................................................................ 1
Thread Locking Sealant............................................ AR
Phillips Screwdriver ..................................................... 1
Torque Wrench, ft. lbs.................................................. 1
Remove the drive belt (1) (Refer to ‘Removing The Drive
Belt’ procedure elsewhere in this section).
Remove the passenger side hub cap if equipped and
using a 3/4" lug wrench, remove the wheel and tire
assembly.
Set park brake and place direction selector in ’Forward’
to place tension on clutches.
Accessing the driven clutch from the passenger side of
the vehicle and remove the bolt (6) and washer (7) from
the driven clutch.
Install the clutch puller bolt in clockwise position until it
bottoms out.
Using an impact tool and a 19 mm impact socket on the
clutch puller bolt, remove the clutch then remove the
clutch puller bolt and slide the clutch from the rear axle
input shaft.
Driven Clutch Repair
Parts must be reassembled in same position as their original
position. Mark all components to facilitate accurate reassem-
bly.
Some minor field repairs may be made to the driven
clutch. Remove the retaining ring (8) and remove the
torque ramp (9) (Ref. Fig. 3). Remove the spring (10)
and the moveable sheave (11).
Inspect the shaft for signs of wear and inspect the bush-
ings for signs of deterioration. If there is wear to the
point of causing vibration, the clutch must be replaced.
Torque Ramp Buttons
Remove any fragments and dirt. Remove the ramp but-
ton (12) by removing the screw (13) and washer (14)
(Ref. Fig. 3). The buttons are replaced by inserting a
new button and screw and tightening firmly. It is good
practice to replace all buttons as a set.
Driven Clutch Assembly
Assemble the moveable sheave (11) to the fixed sheave
(14) and insert the spring (10) in the pilot hole in the
moveable sheave (Ref. Fig. 3). Insert the other end of
the spring in the torque ramp (9) and rotate the ramp
counterclockwise 140
°
before engaging the splines and
inserting the retaining ring (8).
Driven Clutch Installation
Clean the rear axle input shaft and slide the clutch onto
the shaft (Ref. Fig. 3). Install the washer (7) to the clutch
bolt (6) and apply thread sealant to the threads of the
clutch bolt. Install the bolt and tighten to the specified
torque.
STORAGE
If the vehicle is to be out of service for an extended
period of time, the clutches should
not
be coated with
any protecting spray. The drive clutch sheaves may
develop some surface rust which will be removed within
a few minutes of running time. The driven clutch is alu-
minum and requires no treatment.
ITEM
TORQUE SPECIFICATION
2
48 - 55 ft. lbs (66 - 74 Nm)
ITEM
TORQUE SPECIFICATION
6
48 - 55 ft. lbs (66 - 74 Nm)
NOTICE
