Home :: GUIDE - Disassembling / Servicing / Assembling BULLY Clutch

GUIDE - Disassembling / Servicing / Assembling BULLY Clutch

GUIDE - Disassembling / Servicing / Assembling BULLY Clutch

GUIDE

Servicing Bully Clutches - Disassembly and Assembly Tutorial


This month we're showing you how to break down and re-assemble your Bully twin disc clutch, and we'll also give you the tips and tricks to service it and keep it in the best operating order.

*NOTE: This assembly guide shows the 3-disc 3/4" model, but the process is identical for the 1" 4-disc model, except there is an extra friction disc and floater disc.  Also, the screws holding the lever plate to the transmission gear are torx screws on the 1" model.

CONTENTS


1. Remove the Engagement Adjustment Screws

2. Remove the Lever Support Plate

3. Dis-assemble the Lever Support Plate

4. Remove the Pressure Plate assembly

5. Remove the first Friction Disc

6. Remove the first Floater Disc

7. Remove the second Friction Disc

8. Remove the second Floater Disc

9. Remove the third Friction Disc




We have been advised officially by that standard BRAKE CLEANER CAN BE USED TO CLEAN ALL SURFACES (ON OUR Bully CLUTCH - THIS IS ALSO CORRECT FOR THE BULLY CLUTCHES) - specifically friction disc, housing, transmission plates etc. Remember to grease any surfaces which require lubrication prior to assembly.



1. Remove the Engagement Adjustment Screws

Remove the clutch from your kart and clean off any debris and excess chain lube, inspect keyway for wear or deformaties
In our example below, the sprocket has already been removed - if yours is still attached, remove the circlip at the top of the clutch, then the thrust washer, then remove the drum/basket.  On the underside of the basket, remove the circlip then push out the sprocket - if it's stuck, use a nylon hammer or similar to gently knock the sprocket out from the rear of the drum.


Measure the spring height on each spring and record your height, then remove bolts washers and springs. Stock setting is approximately 7mm out.

Bully Clutch

Remove the drum/basket then carefully remove the thrust washer and bearing set - do not lose the pieces - there are 2 thrust washers and one bearing.  If you require a new bearing and thrust washers they can be found here: 

Bully Clutch

Bully Clutch

Bully Clutch

Bully Clutch

Turn the unit over.

Using a socket and ratchet, remove the 6 spring loaded adjustment screws.

Bully Clutch

Bully Clutch

2. Remove the Lever Support Plate

Remove the 6 Lever Support Plate retaining bolts using an allen key tool.

 

Bully Clutch

 

Bully Clutch

3. Dis-assemble the Lever Support Plate


*NOTE: Perform this step in a container if possible to avoid losing the dowel pins - you cannot re-assemble the Bully clutch without them!

Remove the 6 Levers by pulling them upward with the lever support plate facing downwards as per the last step. 
At this stage, check the levers for wear where they rub and egage. Replace if necessary.
The levers may be snug but can be pulled free with very little force. Pull them directly upward. 
Push the dowel pins out of the levers - they will fall out easily and bag them or put them in a small container for later.

 

Bully Clutch

Bully Clutch

 

 

*NOTE: Make sure you perform this step somewhere enclosed, like a box or a plastic ice-cream container in case the levers fall out - you can easily lose dowel pins if they fall out and are not contained*

Carefully lift the Lever Support Plate up and away from the Bully body. Flip the plate as soon as it is clear of the body - do not use jerky movements so as to avoid the levers from falling out. Place carefully on a surface, preferably in a container like an empty plastic ice cream container, or a bucket, or similar vessel.

Check the plate for any wear.
Bully Clutch

4. Remove the Pressure Plate assembly

Slide the pressure plate assembly carefully upwards and off the body of the Bully. Inspect for any wear where the engagement levers rub.
Bully Clutch

5. Remove the first Friction Disc

Remove the friction disc by simply clasping it at the edges at the holes in the basket / housing and taking it out of the body. Check for any defects in the surface and edges of the tangs and replace if worn.

6. Remove the first Floater Disc

Slide the Floater Disc carefully upwards and off the body of the Bully. Check for wear and abnormailties. Replace if necessary.
Bully Clutch


7. Remove the second Friction Disc

Remove the friction disc by simply clasping it at the edges at the holes in the basket / housing and taking it out of the body.
Bully Clutch
8. Remove the second Floater Disc

Slide the Floater Disc carefully upwards and off the body of the Bully. Check for wear and abnormailties. Replace if necessary.
Bully Clutch


9. Remove the third Friction Disc

Remove the friction disc by simply clasping it at the edges at the holes in the basket / housing and taking it out of the body.
Bully Clutch

10.  OPTIONAL Remove the washers from the transmission assembly (there will be two thin washers where the 6 screws attach the lever plate to the transmission plate)

DONE.

Assembly is the reverse procedure from the above.  
*NOTE: When assembling step 2 - lever support plate ensure the blank hole in the transmission assembly core aligns where the lever plate does not have a screw hole.

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