TUNING CHART AND TORQUE CHART LOCATED HERE
WE ARE NOT RESPONSIBLE FOR ANY DAMAGES. BE VERY CAREFUL TO NOT DAMAGE YOUR CLUTCH DURING THIS PROCESS.
TOOLS NEEDED
- 1/2" Drive Impact Gun
- 22mm or 7/8" - Wrench
- 13mm or 1/2" 1/2" Drive Impact Socket
- 17mm - 1/2" Drive Impact Socket • 24mm - 1/2" Drive Impact Socket
- Torque Wrench
- 6mm Allen
- Wrench
- T30 Torx
- T25 Torx
- 8mm or 5/16" wrench
- KWI MAVTOOL clutch tool set or equivalent.
- Clutch Belt removal tool
- Blue Loctite
- KWI Weight Changing Tool (Optional)
- Long 3/8" or 1/4" drive extension
ESTIMATED INSTALL TIME
90 Minutes
PRIMARY CLUTCH DISASSEMBLY AND REASSEMBLY
- Remove belt box cover. (T30 Torx)
- Remove CVT belt. (Clutch Belt removal tool)
- Remove primary clutch bolt. (22mm - 1/2" Drive Impact Socket)
- Thread KWI clutch puller all the way in by hand and then back out 4 turns. (KWI MAVTOOL clutch tool set or equivalent)
- Put Moly grease on the top of the primary puller and on the threads of puller cup bolt. (KWI MAVTOOL clutch tool set or equivalent)
- Insert puller cup into puller plate and secure to governor cup using 6 each M8 bolts. (6mm Allen Wrench)
- Tighten puller cup bolt until governor cup pops off. (STOP TIGHTENING AS SOON AS IT POPS) (1/2" Drive Impact Gun) (24mm or 15/16" - 1/2" Drive Impact Socket)
- Remove puller cup, puller plate and clutch puller then disassemble clutch as required. (You do not need to remove the entire primary clutch from the crankshaft to disassemble and replace the spring)
- To remove and install spring- compress and hold down bearing cover spring pressure for bearing cover removal and installation. (KWI MAVTOOL clutch tool set or equivalent). Tighten 6 screws to 10 ± 1 N•m (89 ± 9 lbf•in)
- Remove the OEM cam arms. (T25 Torx) (8mm or 5/16" wrench)
- Properly configure the magnet setup on the AO.001/GEN6 cam arms for your vehicle using the setup chart.
- Install the AORC/AO.001/GEN6 cam arms in your clutch as required and secure with the pin and nut. Torque nut to 8 ± 0,8 N•m (70 ± 7 lbf•in) (Cam Arms can be removed and installed without any clutch disassembly by using the KWI Weight Changing Tool)
- Reassemble primary clutch, secure with primary clutch bolt and torque OEM primary clutch bolt to 120 ± 8 N•m (89 ± 6 lbf•ft). (KWI 630 primary bolt is to be installed and torqued in accordance with the 630 bolt instructions) (Torque Wrench)
REMOVING AND INSTALLING SECONDARY CLUTCH
- Remove secondary clutch bolt. (17mm or 7/8" - 1/2" Drive Socket) The secondary clutch will slide off shaft.
- [IF YOU HAVE A KWI Floated Secondary] Reinstall secondary clutch in accordance with the KWI Float Mod Instructions.
- [IF YOU HAVE A Stock Secondary] Align splines and slide secondary clutch on shaft. Secure secondary clutch on crankshaft by torquing the secondary clutch bolt to 70 ± 5 N•m (52 ± 4 lbf•ft). (17mm -1/2" Drive Socket) (Torque Wrench) Use the KWI Vorhees Vice or a long 1/4" or 3/8" extension through the helix and spring to hold secondary while torquing.
- Reinstall CVT belt and belt box cover.
SECONDARY CLUTCH DISASSEMBLY AND REASSEMBLY
- Clamp welded nut end of KWI threaded rod in a suitable vise. Place puller cup (without puller cup bolt) over threaded rod.
- Place secondary clutch over threaded rod with helix facing down, turn nut in to compress helix slightly and take tension off of helix bolts. Remove 3 helix bolts. While holding sheaves from turning (by hand) and helix from turning (with a long 1/4 or 3/8 extension inserted thru helix and spring) turn nut out to relax spring tension. Disassemble clutch as required. (22mm or 7/8" - Wrench)
- Install the secondary moveable and fixed sheaves together on the threaded rod with the helix.
- Install the Helix with the spring clocked as specified in the tuning chart.
- To install a KWI GROOVIX please refer to the KWI GROOVIX instructions. GROOVIX hole #1 is marked by a dot then count in a clockwise direction. The GROOVIX helix uses equally spaced holes and does not correlate to the OEM holes.
- Install the large compression washer then nut on the threaded rod until it starts to compress the spring.
- Insert a long 1/4 or 3/8 extension inserted through helix and spring. Hold the sheaves from turning while you rotate the helix CLOCKWISE until the legs clear the rollers. Tighten the threaded rod nut and compress the helix spring.
- Install the 3 helix bolts using BLUE Loctite and torque to 61 ± 6 N•m (45 ± 4 lbf•ft).
MAGNET RPM ADJUSTMENT
This requires the cam arms be removed from the clutch. The weight of the added magnets affects RPM. The more magnets that are installed the lower the RPMS will be. If you remove magnets the RPM will increase
- Remove the cam arms from the clutch. (KWI Weight Changing Tool or follow “Primary Clutch Disassembly and Reassembly” above)
- Remove or add magnets as required.
- AO.001 cam arms have 2 magnet holes - you can place magnets in either hole, but magnets MUST be distributed so that the clutch is balanced. Make sure arms with identical magnets are either placed across from each other or in every other position to maintain clutch balance. Do not overfill magnet slots (FLUSH IS FULL)! Reinstall the cam arms and tighten to spec.
- AO RC cam arms have 3 magnet holes - Add magnets to the single hole in the cam arm that sits outside the clutch to lower engagement RPM and increase low speed belt grip (this hole DOES NOT affect full throttle RPM) (magnets MUST be distributed so that the clutch is balanced). Make sure arms with identical magnets are either placed across from each other or in every other position to maintain clutch balance. Do not overfill magnet slots (FLUSH IS FULL)! Add magnets to either of the 2 holes in the cam arms that are inside the clutch to lower Full throttle RPM's you can place magnets in either hole, but magnets MUST be distributed so that the clutch is balanced. Make sure arms with identical magnets are either placed across from each other or in every other position to maintain clutch balance. Do not overfill magnet slots (FLUSH IS FULL)!