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TEAM PAMI CLUTCH SPRING INSTALLATION
1.
Drain the oil.
2. Drain the coolant. Disconnect hoses from water pump housing.
3. Using a 10mm wrench and socket remove the foot peg bolt that is farthest
forward (peg to frame).
4. Using a 5mm hex key socket or wrench remove the three bolts through the water
pump housing.
5. Using a 5mm hex key socket or wrench remove the two bolts going from the
starter into the side cover.
6. Using a 5mm hex key socket or wrench remove shifter lever. Note position for
reassembly.
7. Using a 5mm hex key socket or wrench remove all the bolts from the perimeter
of the side case, there are three long ones, the rest are the same size.
8. Using a pair of pliers turn the clutch linkage forward to remove the cable
end from linkage.
9. Pull the cover off. Pull straight off and watch where the clutch linkage on
the case points as reference for reassembly. You'll see what I mean when you get
it apart. I think the linkage was facing directly towards the rear of the bike (
3 o'clock
) and with the cable on it pointed towards the motor (
12 o'clock
) so upon removal it had rotated 90 degrees clockwise.
10. Using a 10mm socket remove the bolts holding the clutch springs.
11. Install the new springs; torque the bolts to 89 in/lbs.
12. Clean the gasket with brake cleaner, mine was in great shape and if you
haven't had the cover off before yours should be too.
13. Align the side cover and make sure the teeth on the clutch rod (coming out
from the center of the clutch) are facing the rear of the bike. With the clutch
linkage on the cover running front to back (
3 o'clock
) gently push the cover into place. When the cover slides on the clutch linkage
teeth engage and the clutch linkage ends up where it should.
14. Reinstall the side cover bolts, oil drain plug, water pump housing, and
bolts through the starter bracket and torque all to 89 in/lbs. Clamp your hoses
back on, fill with oil and coolant, reinstall foot peg bolt, and shifter and
you're done.
Submitted by:
Dean Pariseau aka: Barkbiterds
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