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5. Replace bottom cover. 3 1. Drive Belt 2. Brake Shoe and Pad 3. 1/16" (1.6 mm) minimum Figure 9 OS0660 Traction Drive Clutch Adjust traction clutch to compensate for wear of friction wheel when slippage occurs. To adjust traction clutch, place speed selector in First (1) Forward and tip unit forward onto housing. With traction clutch disengaged turn wheels while tightening Adjustment Nut at clutch yoke until wheels begin to drag (Figure 10). Engage and release traction clutch to align clutch linkage. Repeat as necessary. When wheel drag is obtained with linkage aligned, turn nut back three turns. Wheels will then turn freely. 1. Traction Clutch Cable 2. Adjustment Nut Figure 10 1 2 OS1181 3/8" 4 - 16 Speed Selector Adjustment is required if you are unable to shift into all gears. 1. Put unit into Upright Service Position. 2. Disconnect the speed selector rod from the adjustment lever by removing hairpin (Figure 11). 3. Place the speed selector in the fast reverse speed position (Figure 11). 4. Thread the rod adjustment pin along the speed selector rod until it aligns with the mating hole on the speed selector lever. Insert the rod adjustment pin into hole. 5. Move the speed selector to the fastest forward speed position. 6. Insert the hairpin into the rod adjustment pin. 4 5 2 1 1. Speed Selector Rod 2. Rod Adjustment Pin 3. Speed Selector Lever 4. Hairpin Figure 11 OS0021 OSs0190 3 5. Fast Reverse Speed Selector Position Drive Chain Chain should be taut with little or no play in it. To compensate for looseness or excessive tightness in drive chain: 1. Put unit into the Upright Service Position. To maintain proper tightness, a roller is held against the chain. To adjust the roller: 2. Loosen the nut on the hex shaft. 3. Move the shaft to achieve desired tightness. 4. Tighten the nut to lock the hex shaft in position. 5. Torque to 170-180 inch-pounds. NOTE: Check interlock mechanism to ensure proper operation by checking both clutches to be sure they operate freely without binding. 4 - 17 SECTION 5 - HANDLEBARS & CONTROLS SECTION 5 - HANDLEBARS & CONTROLS 1. Chute Crank Handle 2. Speed Selector Lever 3. Set Screw 4. Chute Deflector Remote 5. Attachment Clutch Arm 6. Clutch Cable Spring 7. Clutch Cable 8. Traction Clutch Arm 9. Speed Selector Rod 10.Rod Adapter 11.Traction Clutch Cable Figure 12 DS0161 1 2 3 4 5 6 7 8 9 10 11 5.1 LOWER HANDLEBAR Remove nut and washer attaching lower handlebar to each side of frame and remove lower handlebar. Check parts for wear or replacement. Assemble, using reverse procedure. 5.2 ATTACHMENT CLUTCH HANDLE Remove (2) push nuts, pin and (2) screws holding Clutch Handle and pivot to upper handlebar. Remove pivot and disconnect Clutch Handle from clutch cable. Remove set screw, jam nut and clevis from clutch cable. Remove pin and remove cable. Disconnect spring from lever. Check parts for wear or replacement. Assemble using reverse procedure. 5.3 WHEEL DRIVE CLUTCH LEVER & TRACTION CABLE Remove (2) push nuts, pin, and (2) screws holding pivot and wheel drive clutch lever to upper handle bar. Remove pivot and wheel drive clutch lever. Remove set screw, nut, hair pin and clevis pin holding the clevis to traction clutch cable. Remove set screw in rod adapter and remove traction clutch cable. Check parts for wear or replacement. Assemble using reverse procedure. 5 - 18 5.4 CLUTCH YOKE AND FORK Remove locknut and adapter spacer holding spring assembly in clutch yoke (Figure 13). Remove capscrew, nut, and rod adapter from yoke. Remove cotter pin from end of spring assembly in clutch fork. Remove spring assembly and extension spring. Punch out roll pins holding fork pivot rod in frame and remove rod and clutch fork. Check parts for wear or replacement. Assemble using reverse procedure. 1. Traction Clutch Rod 9. Clutch Fork 2. Spacer 10.Spring Assembly 3. Setscrew 11.Nut 4. Rod Adapter 12.Clutch Yoke 5. Extension Spring 13.Capscrew 6. Cotter Pin 14.Adapter 7. Fork Pivot Rod 15.Adapter Spacer 8. Cotter Pin 16.Lock Nut Figure 13 5 - 19 SECTION 6 - ENGINE SECTION 6 - ENGINE 6.1 ENGINE TROUBLESHOOTING The following troubleshooting chart is to be used to The troubleshooting key is generic and can be used for isolate engine problems and give possible causes and several types of engines. Use only those possible corrective action responses. causes and corrective actions that apply to the unit. TROUBLE POSSIBLE CAUSES (Refer to Key Below) CORRECTIVE ACTION Black Exhaust 20, 22, 25, 29, 31, 32, 33 repair or replace Blue/White Exhaust 4, 20, 2...

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