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CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Primary Clutch Installation
To decrease the risk of damage to the clutch, be
sure to remove all grease from the body of the
clutch since grease penetrating the seal can cause
premature clutch failure or belt slip.
Do not install the bolt (2) with an impact wrench.
To hold the clutch, do not use a pry bar inserted
through the drive clutch as this may damage the
components.
Clean both the engine crankshaft and the primary clutch
bore. Slide the clutch onto the engine crankshaft and
rotate the clutch while lightly pushing the movable sheave
in and out several times to seat the clutch on the tapered
crankshaft (Figure 3).
Install the lock washer (3), conical washer (4) and clutch
washer (5) onto the clutch bolt (2).
Apply thread locking adhesive to the threads of the clutch
bolt (2) and install. Tighten the bolt to the torque value
specified below.
Secondary Clutch Removal
Tool List Qty.
Plastic Faced Hammer ................................................ 1
Clutch Puller, (P/N 608429) ......................................... 1
External Snap Ring Pliers............................................1
Wrench, 18mm ............................................................ 1
Socket, 18mm.............................................................. 1
Impact Socket, 19mm..................................................1
Impact Wrench (Air or Electric).................................... 1
Ratchet ........................................................................ 1
Thread Locking Adhesive .........................................AR
Phillips Screwdriver ..................................................... 1
Torque Wrench, ft. lbs. ................................................ 1
Remove the transmission belt (1) See “Removing The
Transmission Belt”.
Remove the passenger side hub cap if equipped and
remove the wheel and tire assembly.
Set park brake and place direction selector in F to place
tension on clutches.
Access the secondary clutch from the passenger side of
the vehicle and remove the bolt (6), lock washer (7) and
conical washer (8) from the secondary clutch.
Install the clutch puller bolt until it bottoms out.
Remove the clutch, then remove the clutch puller bolt and
slide the clutch from the rear axle input shaft.
Secondary Clutch Repair
The parts must be assembled again in same position as
their original position. Mark all components to facilitate
accurate reassembly. Some small field repairs may be
made to the secondary clutch.
Remove the retaining ring (9) and remove the outer
spring retainer (10) (Figure 3). Remove the spring (11),
inner retainer spring (12) and the movable sheave (13).
Inspect the shaft for indications of wear and inspect the
bushings for indications of damage. If there is wear to the
point of causing vibration, the clutch must be replaced.
Secondary Clutch Assembly
Assemble the movable sheave (13) to the fixed sheave
(14) and insert the spring (11) and inner retainer spring
(12) in the pilot hole in the movable sheave (Figure 3).
Insert the other end of the spring in the outer retainer
spring (10) and rotate counterclockwise 140° before
engaging the splines and inserting the retaining ring (9).
Secondary Clutch Installation
Apply a layer of anti-seize compound on the rear axle
input shaft and slide the clutch on to the shaft.
Install lock washer (7) and conical washer (8) to the clutch
bolt (6) and apply thread locking adhesive to the threads
of the clutch bolt.
Install the clutch bolt and tighten to the torque value spec-
ified below.
STORAGE
If the vehicle is to be out of service for an extended period
of time, the clutches must not be coated with a protecting
spray. The primary clutch sheaves can develop some sur-
face rust that is removed within a few minutes of running
time. The secondary clutch is aluminum and does not
need any maintenance.
Item Torque Specification
2 55 - 62 ft. lbs. (74 - 84 Nm)
Item Torque Specification
6 55 - 62 ft. lbs. (74 - 84 Nm)
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