CLUTCH 110 Nim (11.0 kg-m, 80 Teb) 110N lm (11.0 kg-m, 80 ft-lb) 12 Nem (1.2 kam, 9 frlb) 8-08. CLUTCH SERVICE INFORMATION 81 PRIMARY DRIVE GEAR 87 TROUBLESHOOTING 8-1 GEARSHIFT CAM 89 RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER REMOVAL 8.2 INSTALLATION 8.9 CLUTCH a2 SERVICE INFORMATION GENERAL (This section covars removal and installation of the clutch, gearshift cam and right crankcase cover. All these operations ‘can ba performed with the angine in the framo. © Whan the clutch discs are replaced, coat new dises with engine oll prior to assembly. SPECIFICATIONS El i Tre STANDARD sevice UNIT hich Lever fice pay ft br endl Spring eo longi Z7mmi7in) | 43.4 wm (70) Sing pelod/enath 3021 FRE. 6 mr (6.2 + 831 bit i = se thickness 2.92~6.08 nen (0.115-0.12 Fomm (1A) Plate warege — 0.15 mm 0.06 i) [Tuten outer 1, Fi:000~27-024 men (1.08501.0688 n) | 27.08 mm (1.055 I [Sure ite OB. | 26.080 26.960 mn (1.0690 1.0622 in) _| 26,01 mun (1.060 mn) | 1.9, | 21.890 22.035 mm 0,£657-0,8675 in) | 22.05 mn (0.858 n) | TORQUE VALUES: | Clutoh took nut 110 Nem [11.0 kg.m, 80 ftby Prey dive ger ma 110 tem 11.0 keen, £0 Coast cam at Tan (12 kp 9 fsb) Apo fckng agent tote vac Stopper arm bolt 25 Nem (2.6 kg-m, 18 ft-lb) Right crankcase cover bolt/nut 12.Nem (1.2 ka-m, 9 ft-lb} TOOLS Common Garh eonter holier ©7724 0050001~oreauvelontcommerily avlebe in US.A. Goo hoor C7724 0010100" Net salable in Us TROUBLESHOOTING Faulty clutch operation can uouslly be corracted by adjusting the clutch lever Free play, Clutch Slips When Accelerating Excessive Lover Prossu + No free play + Clutch cable kinked, damaged, or dirty + Discs worn + Lifter mechanism damaged + Springs week Clutch Operation Feols Rough Clutch Will Not Disengage + Outer drum slots rough + Too much free play + Diny oluten cable + Plates warped Motorcycle Creeps With Clutch Disengaged + Too much free play ‘Laces warped 8-1CLUTCH RIGHT CRANKCASE COVER REMOVAL Drain oil from engine and oil tank (page 2-3) Remove the following components: © Breke pedal (eago 12-10) Oil pipe {page 6-3) Remove the right crankcase cover bolts, nuts and right crank- mare steps. Remove the dowel pins and gasket. OIL SEAL REPLACEMENT Check for tho oil e00! for damago or deterioration. Remove the snap ring and oil seal. Install the new cil seal ard snap ring. NOTE + Make sure the snep ring is seatad in the groove in the right erankease cover CLUTCH REMOVAL Remove the right crankcese cover. Remove the four clutch bolts and springs Nore + Loosen the bolts in a steps. 13) PRESSURE PLATE 8-2CLUTCH Femove the push rod tip and clusch iter roa. Unstake the clutch lock nut with a dill or grinder, Fomove tho clutch lock nut, plain washer and clutch center, holding with the clutch center holder. TOOL: Clutch conter holder 07724—0050001 (or equivalent commercially avallable in U.S.A, Remove the clutch outer and cluten outer quide Inepoct tho clutch liftor rod tor wear or damage. 41) LIFTER ROD. Check the lifter rod fer straightness by rolling the rod on a tlat surface,CLUTCH INSPECTION © CLUTCH SPRING Measure the fies length of each spring SERVICE LIME 3.1 mm (1.70 ind Replace if shorter than the service lima, nore + Cluteh springs should be replaced as asset if one er mere are beyond the service limit. * CLUTCH DISC Replace the discs if they show signs of scoring or discolora- ton Measure the disc thickness. SERVICE LIMIT: 2.6 mm (0.10 in} NOTE + Clutch discs and plates should be replaced as a set if any fre is beyond the service limit © CLUTCH PLATE Chack for plate warpage on a suriace plato, using a fealar gouge ‘SERVICE LIMIT: 0.3 mm (0.01 in) (2) PRESSURE PLATE © PRESSURE PLATE BEARING (1) BEARING, Turn the bearing inner rece wit your Fingor The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate Replace the beering with a navy one, if necessary.CLUTCH SSeS © CLUTCH CENTER (1) CLUTCH CENTER Cheek the teeth of the clutch cent cracks. fer wear, damage or (2) 7COTH © CLUTCH OUTER AND OUTER GUIDE Chesk the slats in the outer drum for nicks, cuts or indentations made by the fricton ciscs. Measure the I,D. of the olutch outer and the 0.0. of tho outor guide. SERVICE LIMITS: Cluteh outer 10+ 27.08 mm (1.085 in) Clutch outer guide 0.0: 26.91 mm (1.059 in} 1.D.: 22.05 mm (0.868 ind ‘Measure the mainshaft 0.D. at the clutch outer guide area. [SERVICE LINIT: 21.91 mm (0.863 in} Calculate the mainshafi-to-cluteh outer guide clearence. SERVICE LIMIT: 0.14 mm (0.006 int INSTALLATION gi) CLUTCH OUTER le iz clues ourer 8-5CLUTCH Install tho clutch lock nut and tighten it holding with curon F(1) CLUTCH CENTER 01 center holder. TORQUE: 110 Nem (11.0 kgm, 80 ft-1b) TOOL: Clutch center holder 077240050001 oF equivalent commarcialy available in U.S.A. ‘Stake the clutch lack nut with a punch: Inaort the clutch lifter rod through tho mainshatt Coot the 7 cisce ond 6 plates with clean engine cil and install them as shown, on CLUTCH PLATE (5 pieces) (2) DISC (7 pieces) Install the clutch push ro¢ tp into the mainshat B (2) CLUTCH DISC AND PLATESCLUTCH Install the pressure plate, clutch springs and clutch belts, and 11) CLUTCH SPRINGS 4 ‘tighten the bolts in a ciisscross pattern in two or mora steps. PRIMARY DRIVE GEAR REMOVAL Remove the pulse generator by removing the bolts and aromet. Romove the follewing componente: = Cluteh (page 8-2) — Oil pump page 2-5 ‘Temporarily install she clutch outer, then inetall the gear holder between the primary drive gear and driven gear as shown, TOOL: Goer holder Remove the primary drive gear nut, then remove the gear holder and clutch outer (2) PRIMARY DRIVE! SEAR NUT Famove the foloing JT Finan’ Baie oNreshor ioe = Gt ump drive gor ; — pulse generator rotor — primary drive ge 3) OL P DRIVE GEARCLUTCH INSTALLATION Install the primary crive gear over the crankshaft NoTE di Fs, . + the pulse generator rotor and oil pump ive gear wit only fe go on in one position because of the extra wide aligning f i spline ‘ é ‘ amt 4 ee i Install tha pulse generator rotor onto the crankshaft. (3) “OUT SIDE" MARK Inatall the oll pump drive goar and washar onto the crankcheft. NoTE Install the washer with the “OUT SDE" mark cing out. TT PRINARY DRIVE ‘Temporarily install the clutch outer, and set the gear holder be- Gran NUT s ‘tween the primary drive geer and driven gear as shown. Install and tighten the primary drive gear nut. TORQUE: 110 Nem (11.0 kg-m, 80 flo) ToL: Gear holder 07724—0010100 Not available in U.S.A. Remove the gear holder end clutch outer. Install the fellowing: = oil pump (page 2-11) — eluter (page 8-6) Install the pulse gonorator and secure it with two belte, and [AUT the gromet into the groove in the right crankcase, NOTE + Remove any metal chips that may be stuck to the pulse generator maanet ll ere _CLUTCH GEARSHIFT CAM REMOVAL Remove the following: = clutch ipage 8-2) — bolt, washer, stopper arm and spring — bolt and gearshift cam 15] WASHER INSTALLATION 71) HOLE 9 RR “Seon Install the gearshift cam on the shift drum, aligning the hole in ES ‘the cam with the dowel pin. Apply @ locking agent to the threads of the gearshift cam bolt, and tighten It to the specified torque. TOROUE: 12 Nem (1.2 ko-m. 9 ft1b) Install the spring, stopper arm, washer and bolt, holding the stepper arm with a screw driver. Tighten the stopper arm bolt. Install the clutch {page &-6) RIGHT CRANKCASE COVER INSTALLATION Instell the dowel pine and a now gasketCLUTCH Install the right orankcase cover, and install anc tighten the bolts and nuts in a crisscross pattern in two or mora steps. TORQUE: 12 Nem (1.2 kg-m, 9 feb} Insiall the following componentes: pipe (oage 6-20) — Brake pedal ipago 13.11) Fill the engine and of tank with recommended oil (page 2-2). Adjust the followings: = Clutch lever free play (page 3-12) Brako podal foo play {page 3-11) (17 3RARE PEDAL] Sm