GUIDE

Servicing NORAM Cheetah Clutches - Disassembly and Assembly Tutorial


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

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 Floater Disc

7. Remove the second Friction Disc

8. Separate the Basket & Drive sprocket assembly from the Transmission Gear assembly

9. Dis-assemble the Transmission Gear assembly

10. Dis-assemble the Basket and Drive Sprocket assembly


We have been advised officially by Noram that standard BRAKE CLEANER CAN BE USED TO CLEAN ALL SURFACES - 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
Position the clutch sitting on the sprocket.
Measure the spring height on each spring and record your height, then remove bolts washers and springs. Stock setting is approximately 5 turns out.


Using an allen key tool, remove the 6 spring loaded adjustment screws.  (Replacement part: CLCHP21 )



2. Remove the Lever Support Plate

Remove the 6 Lever Support Plate retaining bolts using an allen key tool.  (Replacement part CLCHP00 )

*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 (Replacement part CLCHP18 ) up and away from the Cheetah 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.



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 Cheetah clutch without them!

Remove the 6 Levers (Replacement part CLCHP16 x6 ) 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 (Replacement part CLCP17 x6) out of the levers - they will fall out easily and bag them or put them in a small container for later.

Upon reassembly, be sure to lubricate clutch lever pivots lightly.




4. Remove the Pressure Plate assembly

Slide the pressure plate assembly (Replacement part CLCHP14 ) carefully upwards and off the body of the Cheetah. Inspect for any wear where the engagement levers rub.



5. Remove the first Friction Disc

Remove the friction disc (Replacement part CLCHP11 ) 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 Floater Disc

Slide the Floater Disc (Replacement part CLCHP12 ) carefully upwards and off the body of the Cheetah. Check for wear and abnormailties. Replace if necessary.



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.



8. Separate the Basket & Drive sprocket assembly from the Transmission Gear assembly

Turn the body of the Cheetah over so that the drive sprocket is facing upward


Slide the basket upwards and over the transmission gear shaft. Set it aside - we will dis-assemble this later.



9. Dis-assemble the Transmission Gear assembly

Remove the first thrust washer (Thrust Washer & Bearing kit Replacement part CLCHP678 )


Remove the thrust washer bearing


Remove the second thrust washer.

Clean and lightly re-grease washers and bearing (this should be done on a regular basis)


With the second thrust washer removed, the six transmission gear retainer bolts (Replacement part CLCHP00 ) will be visible. Using an allen key tool, remove all six bolts.


Remove the circlip (Replacement part CGTCC1 ) using a circlip remover then separate the transmission gear (Replacement part CLCHP10 ) from the transmission plate (Replacement part CLCHP09 ) by sliding the plate upwards and over the top of the transmission gear shaft



10. Dis-assemble the Basket and Drive Sprocket assembly

Remove the black thrust washer. (Replacement part CGTTW1 )


Flip the housing over and remove the large circular circlip. This can be done easily with two flat-head screwdriver - hold the blunt end of the circlip with one screwdriver while gently sliding the second screwdriver under the sharp part of the circlip (Replacement part included with all replacement sprockets). It will pop up over the top of the nylon sprocket retainer. 

Remove the circlip (Replacement part included with all replacement sprockets)


Push the sprocket out of the housing / basket (Replacement part CLCHDR ) . A good tool to use is a half inch socket extension - use it like a slide hammer and knock the sprocket downwards with the housing set as pictured above and below.


Upon re-assembly, lube the idle bearing or bush in the sprocket assy.

Assembly is the exact reverse procedure of the dis-assembly above.