AIRLESSCO GS6250 - Manual (Page 17)

Clutch Replacement
3A1187E 17
Clutch Replacement
Removing the Clutch
Refer to the following parts diagrams: Belt Tensioning,
Clutch Assembly, and Power Unit Assembly
1. Remove the gear box cover (Power Unit Assembly,
item 1) by disconnecting fluid hose to the manifold
filter by unscrewing the four allen head bolts (Power
Unit Assembly, item 36).
2. Disconnect the Fluid Pump, page 11.
3. Pull off the spacer tubes (Power Unit Assembly, item
30) and drop the sleeve bearing down and off. Slide
the connecting rod off the gear box.
4. Remove the top cover (Power Unit Assembly, item
2) by unscrewing the 6 mounting screws. Be careful
not to lose the 6 matching grommets.
5. Remove the bottom cover (Power Unit Assembly,
item 14) by unscrewing the 2 bolts and nuts.
6. Remove the splash cover (Power Unit Assembly,
item 12) from the clutch brackets and spacer tubes.
7. Disconnect the two clutch from the electrical control
board leads and clutch the spring (Clutch Assembly,
item 9) from the spacer tube.
8. Loosen (do not remove completely) the block ten-
sioner’s set screws (Belt Tensioning, item 6) to
detension the belt.
9. Loosen (do not remove) the four plate bolts.
10. Pull the cog belt loose from the engine shaft god
pulley and let hang loose on the clutch cog pulley.
11. Remove the two vertical bracket screws. (Power
Unit Assembly, item 20)
12. Remove the four horizontal screws throughout the
gearbox plate (Belt Tensioning, item 5) and lift the
gear box off the machine.
13. Place gearbox in vice by gripping the flat part of the
drive crank allowing the clutch assembly to face up.
Use caution and not allow gearbox to swing and
damage casting against vice.
14. Hold coupling screw, with 13/16” wrench, then with
5/16” allen wrench, screw differential screw out of
coupling screw and gearbox shaft.
15. Remove the coupling screw from the clutch bore.
NOTE: After extended use the coupling screw can hang
up inside of the clutch bore. Tapping on the side of the
coupling screw and/or the use of the lightweight oil or
break free product can ease the removal process. In
extreme cases, screw the differential screw large thread
size in, then place a washer and nut on the small thread
side. This allows pulling or prying on the coupling screw
in order to remove it.
16. The clutch and other components can now be slid
off the gear box shaft.
Inspecting the Clutch
1. Inspect clutch and belt, replace as necessary.
Installing the Clutch
Refer to the following parts diagrams: Belt Tensioning,
Clutch Assembly, and Power Unit Assembly
1. With gearbox held in a vice vertically as previously
described, place first spacer, and bearing, onto
gearbox shaft. See Clutch Assembly, page 27
2. Inspect snap rings (2), into recesses of cog pulley
portion of clutch. Place cog pulley portion of clutch
with cog belt attached onto shaft.
3. Place second spacer, into cog pulley portion of
clutch. This spacer will rest on the first bearing,
installed.
4. Insert second bearing, on top of upper snap ring.
5. Lay removable spacer on top of last bearing. If the
clutch air gap is larger than .024”, do not use remov-
able spacer. Put spacer over removable spacer, if
used, and top bearing.
6. Place coil portion of clutch down onto cog pulley
portion of clutch and center on gearbox shaft.