Pioneer 1200 Maintenance Service Manual page 283

TORQUE CONVERTER
DRIVEN CLUTCH
See General Warning, Section 1, Page 1-1.
DRIVEN CLUTCH REMOVAL
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle is in NEUTRAL. Chock
the wheels.
2. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-2.
3. Disconnect the spark plug. See WARNING "To avoid unintentionally starting..." in General Warning,
Section 1, Page 1-2.
4. Remove the drive belt as instructed. See Drive Belt Removal on page 17-3.
5. Remove the bolt (11) and mounting washer (12) from the clutch shaft (Figure 17-16, Page 17-14).
6. Grasp the driven clutch assembly and slide it off the shaft.
7. Leave the key (9) in the keyway (Figure 17-16, Page 17-14).
DRIVEN CLUTCH DISASSEMBLY
1. Use external snap ring pliers to remove the retaining ring (2) (Figure 17-17, Page 17-15). See following
WARNING.
∆
WARNING
• Do not place fingers under the cam when removing the cam. The moveable face may spin
when the cam buttons release from the cam ramps, resulting in severe personal injury.
2. Insert a puller plug (CCI P/N 1014507) (Figure 17-18, Page 17-15) into the shaft bore and use a driven
clutch cam puller (CCI P/N 1014508) to remove the cam (4) from the fixed face shaft (8). Retain the key
(3) (Figure 17-16, Page 17-14).
3. Remove the spring (5) (Figure 17-16, Page 17-14).
4. Slide the moveable face (7) off the fixed face shaft (8) (Figure 17-16, Page 17-14).
DRIVEN CLUTCH INSPECTION
1. Inspect the cam (4) for excessive wear. Replace it if necessary (Figure 17-16, Page 17-14).
2. Inspect the drive buttons (6) for excessive wear. Replace if necessary. To remove the drive buttons,
remove the socket-head cap screws and then the buttons.
3. Inspect the smooth surface on the fixed and moveable face assemblies. Assemblies must be replaced
if surfaces are worn more than 0.060-inch (1.5-mm).
4. Inspect the bronze bearing in the moveable face. If the bearing bore diameter is more than 1.384-inch
(35.15-mm), the entire moveable face assembly must be replaced.
5. Inspect the shaft of the fixed face assembly. There should be no noticeable wear. Replace the shaft if it
is worn, scratched or damaged.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
17
Driven Clutch
Page 17-13