CLUTCH SPRING

Clutch springs should be replaced as a set if one or more is below the service limit.

Measure the clutch spring free length. SERVICE LIMIT: 43.7 mm (1.72 in)

CLUTCH SPRING

CLUTCH SPRING

CLUTCH DISCS

CLUTCH DISC

CLUTCH SPRING

Check the clutch discs for signs of scoring or discol­oration.

Replace the clutch Measure the thickness of each disc. discs and Plazas SERV1CE UMIT: 2.85 mm (0.112 in)

CLUTCH PLATE

CLUTCH SPRING

CLUTCH PLATES

Check the plates for excessive warpage or discolor­ation.

Check the plate warpage on a surface plate using a feeler gauge.

Replace the clutch Measure the thickness of the plates. d, scs and plates n SERV|CE L|M(T; 015 mm {0 006 jn)

CLUTCH CENTER

Check the clutch center for nicks, indentations or abnormal wear made by the clutch plates.

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CLUTCH SPRING

CLUTCH LIFTER/NEEDLE BEARING

Check the lifter for wear or damage.

LIFTER ROD

NEEDLE BEARING

CLUTCH SPRING

Check the needle bearing for wear or damage. Assemble the clutch lifter, needle bearing and washer.

Turn the washer with your finger and make sure the needle bearing turns smoothly.

Replace the clutch lifter, needle bearing and washer as a set if necessary.

CLUTCH LIFTER ROD

Check the clutch lifter rod for damage and straight­ness.

CLUTCH OUTER

OUTER

CLUTCH SPRING

PRIMARY DRIVEN GEAR

Check the clutch outer for nicks, indentations or abnormal wear made by the clutch discs.

Check the serrated teeth of the primary driven gear for wear or damage.

CLUTCH OUTER GUIDE

NEEDLE BEARINGS

CLUTCH SPRING

Check the clutch outer guide for abnormal wear or damage.

NEEDLE BEARING

CLUTCH SPRING

CLUTCH OUTER GUIDE

Check the needle bearing for wear or damage.

Check the mainshaft for wear or damage at the slid­ing surface of the clutch outer guide.

CLUTCH SPRING

NEEDLE BEARING

DUST SEAL

CLUTCH LIFTER LEVER

CLUTCH LIFTER LEVER

CLUTCH SPRING

Check the clutch lifter lever for damage.

Check the dust seal and needle bearing for wear or damage.

Apply grease to the oil seal lips.

INSTALLATION

CLUTCH SPRINGCLUTCH SPRING

CLUTCH OUTER

~ 1

OUTER GUIDE

THRUST WASHER

"1

CLUTCH DISC A

CLUTCH

CENTER

^0

CLUTCH DISC A

LOCK NUT

1

NEEDLE BEARINGS

CLUTCH DISC В

THRUST WASHER LOCK WASHER

WASHER

LIFTER ROD

CLUTCH LIFTER NEEDLE BEARING PRESSURE PLATE

CLUTCH PLATE

12 N-m (1.2 kgf-m, 9 lbf-ft) CLUTCH SPRING

Apply molybdenum oil solution to the clutch lifter lever cam area.

Install the clutch lifter lever into the left crankcase. Install the clutch lifter lever stay and bolt.

Connect the clutch cable to the clutch lifter lever.

LIFTER LEVER

CLUTCH CABLE

— — t

stay!

BOLT

Install the spacer, drive sprocket cover, and bolts.

CLUTCH SPRINGApply molybdenum oil solution to the clutch outer guide inner surface and clutch outer needle bearing rolling area.

NEEDLE BEARINGS

CLUTCH OUTER GUIDE

Apply transmission oil to the needle bearing.

Install the clutch outer guide and needle bearings onto the mainshaft.

Apply oil to the clutch outer sliding surface. Install the clutch outer and thrust washer.

Install the right crankcase cover (page 11-6).

Install the clutch center onto the mainshaft.

Install a new lock washer by aligning its grooves with the clutch center ribs.

Apply transmission oil to the threads and seating surface of the clutch center lock nut.

THRUST WASHER

Install the thrust washer and lock nut.

Tighten the lock nut to the specified torque using

the special tool.

TOOL:

Clutch center holder 07724-0050002 or

equivalent com­mercially avail­able in U. S.A.

TORQUE: 80 N m (8.2 kgf m, 59 Ibf ft)

Bend the tabs of the lock washer up against the clutch center lock nut.

CLUTCH SPRING

LOCK NUT І

Coat the clutch plates and discs with clean transmis­sion oil.

Install the clutch disc A at first, then install the seven clutch plates and six clutch discs В alternately.

Install the clutch disc A at the end.

CLUTCH SPRING

PLATES

NEEDLE BEARING —та

CLUTCH LIFTER

Apply transmission oil to the clutch lifter and lifter rod contact surface.

Insert the clutch lifter rod into the mainshaft.

Install the clutch lifter.

Apply transmission oil to the needle bearing and washer.

Install the needle bearing and washer to the clutch lifter.

LIFTER ROD

WASHER ■

К.» • I • I

Install the pressure plate.

Install the clutch springs and bolts.

Tighten the bolts to the specified torque in a criss­cross pattern in two or three steps.

TORQUE: 12 N m (1.2 kgf-m, 9 Ibf ft)

Apply oil to a new O-ring and install the clutch cover.

CLUTCH SPRING

Tighten the cover bolts in a crisscross pattern in two or three steps.

Install the brake pedal (page 16-24).

Adjust the clutch lever freeplay (page 4-31).

Fill the cooling system with the recommended cool­ant and bleed the air (page 7-7).

Fill the engine with the recommended transmission oil (page 4-23).

Start the engine and check for oil leaks.

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