Kawasaki J300 - Service manual > Clutch/Driven Pulley

Clutch/Driven Pulley Removal

• Remove the drive pulley (see Drive Pulley Removal).
• Hold the clutch outer [A] with the flywheel & pulley holder [B], and remove the clutch outer nut [C].

  Special Tool - Flywheel & Pulley Holder: 57001-1605

• Remove:
  Collar [D]
  Clutch Outer

• Remove the clutch/driven pulley assembly [A] together with the drive belt [B].

Clutch/Driven Pulley Installation

• Check the needle bearing [A] and outer bearing [B] for wear or damage.

  If the bearing is noisy or have excessive play, replace it with a new one (see Driven Pulley Face Bearing Replacement).

• Clean the driven pulley faces and remove any grease from them.
• Lay the drive belt on the driven pulley and install the clutch/driven pulley onto the drive shaft.

NOTE

• Lay the drive belt so that its arrow marks [A] face forward.

• Install:
  Clutch Outer [A]
  Collar [B]
• Hold the clutch outer with the flywheel & pulley holder [C].

  Special Tool - Flywheel & Pulley Holder: 57001-1605

• Tighten the clutch outer nut [D].

  Torque - Clutch Outer Nut: 54 N*m (5.5 kgf*m, 40 ft*lb)

• Install the removed parts (see the appropriate chapters).

Clutch/Driven Pulley Disassembly

• Hold the clutch/driven pulley assembly [A] with the clutch spring compressor [B].

  Special Tools -
   Clutch Drive Nut Fitting [C], [D]: 57001-Y022
   Clutch Spring Compressor: 57001-Y023

• Set the clutch spring compressor in a vise and remove the clutch drive plate nut.
• Loosen the clutch spring compressor and disassemble the drive pulley assembly.

• Remove the seal collar [A].

• Pull out the guide roller pins [A] and guide rollers.
• Remove the movable driven face [B] from the driven face [C].

Clutch/Driven Pulley Assembly

• Replace the O-rings [A] and oil seals [B] with new ones.
• Apply grease to the O-rings and oil seals lips, and install them onto the movable driven face [C].

• Clean the driven pulley faces and remove any grease from them.
• Install the movable driven face onto the driven face [A].
• Apply grease to the guide rollers [B] and guide roller pins [C] and then install them into the holes of the driven face.
• Install the seal collar [D].
• Remove any excessive grease.

NOTE

• Be sure to clean the driven face off any grease.

• Set the driven pulley assembly [A], driven face spring [B], collar [C] and clutch assembly [D] onto the clutch spring compressor.

• Compress the clutch spring compressor [A] and install the clutch drive plate nut.

  Special Tools -
   Clutch Drive Nut Fitting [B], [C]: 57001-Y022
   Clutch Spring Compressor: 57001-Y023

• Set the clutch spring compressor in a vise and tighten the clutch drive plate nut to the specified torque.

   Torque - Clutch Drive Plate Nut: 54 N*m (5.5 kgf*m, 40 ft*lb)

Clutch Disassembly

• Remove the circlips [A] to disassembly the clutch.

NOTE

• Keep grease off the clutch linings [B].

Clutch Assembly

• Install the damper rubbers [A] on the drive plate pins [B].
• Install the clutch weights/shoes [C] and clutch springs [D].
• Replace the circlips [E] with new ones.
• Set the new circlips in the groove.

Clutch/Driven Pulley Inspection

• Inspect the clutch outer for damage.

  If there is any damaged part, replace it.

• Measure the clutch outer inside diameter [A].

  If the clutch outer is worn over the service limit, replace it.

Clutch Outer Inside Diameter
 Standard: 152.1 - 152.2 mm (5.988 - 5.992 in.)
 Service Limit: 152.2 mm (5.992 in.)

• Measure the driven face spring free length [A].

Driven Face Spring Free Length
 Service Limit: 136 mm (5.35 in.)

• Check the driven face for damage.

  If there is any damaged part, replace it.

• Measure the driven face outside diameter [A].

  If the driven face is worn over the service limit, replace it.

Driven Face Outside Diameter
 Standard: 39.965 - 39.985 mm (1.5734 - 1.5742 in.)
 Service Limit: 39.94 mm (1.572 in.)

• Check the movable driven face for damage.

  If there is any damaged part, replace it.

• Measure the movable driven face inside diameter [A].

  If the movable driven face is worn over the service limit, replace it.

Movable Driven Face Inside Diameter
 Standard: 40.000 - 40.025 mm (1.5748 - 1.5757 in.)
 Service Limit: 40.06 mm (1.577 in.)

Driven Pulley Face Bearing Replacement

• Remove:
  Driven Pulley Face (see Clutch/Driven Pulley Disassembly)
  Needle Bearing

Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058

• Remove the circlip [A].

Special Tool - Inside Circlip Pliers: 57001-143

• Remove the outer bearing by tapping with a suitable bar [A].

• Replace the bearings with new ones. -Press the outer bearing until it is bottomed.

  Special Tool - Bearing Driver Set [A]: 57001-1129

  • Install the outer bearing so that the sealed end faces outward.

    Install the new circlip.

  Special Tool - Inside Circlip Pliers: 57001-143

• Press the needle bearing until it is bottomed.

  Special Tool - Bearing Driver Set: 57001-1129

• Apply grease to the drive face bore areas [A].

See also: