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8. DRIVE AND DRIVEN PULLEYS

8-0

YUP 25 0

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DRIVE AND DRIVEN PULLEYS

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SCHEMATIC DRAWING ---------------------------------------------- 8- 1

SERVICE INFORMATION -------------------------------------------- 8- 2

TROUBLESHOOTING ------------------------------------------------- 8- 2

LEFT CRANKCASE COVER------------------------------------------ 8- 3

DRIVE PULLEY -------------------------------------------------------- 8- 4

CLUTCH/DRIVEN PULLEY ------------------------------------------ 8- 8

Summary of content (16 pages)

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8. DRIVE AND DRIVEN PULLEYS YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. SPECIFICATIONS Item Movable driven face bushing I.D. Driven face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D. Drive pulley collar O.D. Weight roller O.D.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 LEFT CRANKCASE COVER REMOVAL Remove the four bolts on the left crankcase surface cover. Cover Air Tube Band Bolts Remove the left crankcase cover bolts and left crankcase covers. Remove the seal rubber and dowel pins. Left Crankcase Cover INSTALLATION Install the dowel pins and the gasket. Dowel Pins Gasket Install the left crankcase cover. Install and tighten the left crankcase cover bolts.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Universal Holder DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and washer. Remove the drive pulley face. Special Universal Holder E017 Drive Pulley Face Remove the drive belt from the movable drive face. Movable Drive Face Drive Belt INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 22.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Drive Pulley Collar Remove the movable drive face assembly. Remove the drive pulley collar. Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate. Remove the weight rollers. Weight Roller INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 22.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Measure the movable drive face bushing assembly I.D. Service Limit: 27.13mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface. Service Limit: 26.90mm replace if below ASSEMBLY Install the weight rollers into the movable drive face. ＊• The direction of all weight rolls is same. The color side is towards to clockwise.
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. DRIVE AND DRIVEN PULLEYS YUP 250 Ramp Plate Install the ramp plate. Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly Lay the drive belt on the driven pulley. Set the drive belt on the drive pulley collar.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Drive Pulley Face Install the drive pulley face, washer and drive face nut. Drive Face Nut Hold the drive pulley with the universal holder and tighten the drive face nut. Torque: 88.2_ 98N-m Washer Universal Holder Special Universal Holder ＊• E017 Do not get oil or grease on the drive belt or drive pulley faces. Drive Pulley Clutch Outer CLUTCH/DRIVEN PULLEY Remove the left crankcase cover. (!8-3) Remove the drive pulley and drive belt.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊• Clutch Spring Compressor Be sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor E034 Set the tool in a vise and remove the clutch drive plate nut.
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8. DRIVE AND DRIVEN PULLEYS Guide Roller Pin YUP 250 Guide Roller Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Movable Driven Face Remove the oil seal from the movable driven face. O-ring Oil Seal INSPECTION Measure the driven face spring free length. Service Limit: 130.5mm replace if below Check the driven face assembly for wear or damage. Measure the driven face O.D. Service Limit: 39.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 40.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play. Drive the inner needle bearing out of the driven pulley face. ＊• Discard the removed bearing and replace with a new one. Inner Bearing Snap Ring Remove the snap ring and drive the outer bearing out of the driven face.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Press a new needle bearing into the driven face. Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. ＊• Keep grease off the clutch linings.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 CLUTCH ASS EMBLY Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips. Circlips Drive Plate Movable Driven Face CLUTCH/DRIVEN PULLEY AS SEMBLY Clean the pulley faces and remove any grease from them. Apply grease to the O-rings and install them onto the moveable driven face.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Guide Roller Pin Guide Roller Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face. Driven Face Seal Collar Install the seal collar. Remove any excessive grease. ＊• Movable Driven Face Be sure to clean the driven face off any grease. Set the driven pulley assembly, driven face spring and clutch assembly onto the clutch spring compressor.
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8. DRIVE AND DRIVEN PULLEYS YUP 250 Clutch Outer Install washer and the clutch outer nut. Hold the clutch outer with the universal holder to tighten clutch outer nut. Torque: 49.0_ 58.