CLUTCH 6-15

Clutch

•Apply molybdenum disulfide grease to the pusher end [A].

•Install the washer [B], spring [C], bearing [D] and shim [E] to the pusher.

•Install the pusher to the drive shaft [F] direction as shown in the figure.

•Align the projections [A] of the spring plate [B] to the grooves [C] of the sub clutch hub [D] to install the spring plate on the sub clutch hub.

•Install the clutch springs and spring holders, and tighten the clutch spring bolts.

Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•Install the clutch cover (see Clutch Cover Installation).

Spring Plate Free Play Measurement

Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy” or pulsate when pulled.

•Hold an extra drive shaft in a vise and install the following clutch parts on the shaft (see Clutch Installation).

Spacer [A]

Sleeve [B]

Needle Bearing [C]

Clutch Housing [D] Spacer [E]

Clutch Hub [F]

Sub Clutch Hub [G]

Friction Plates (36 Lining Blocks) [H] Steel Plates [I]

Spring Seat [J] Spring [K]

Friction Plates (48 Lining Blocks) [L] Clutch Spring Plate [M]

6-16 CLUTCH

Clutch

•Engage the clutch hub with the sub clutch hub.

•To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate.

•Move the clutch housing gear back and forth [C]. The difference between the highest and lowest gauge readings is the amount of free play.

Drive Shaft [D]

•Measure the spring plate free play.

Spring Plate Free Play

Usable Range: 0.05 0.70 mm (0.002 0.028 in.)

If the free play is not within the usable range, change all of the friction plate and measure the free play again.

If the free play is not within the usable range, adjust the free play (see Spring Plate Free Play Adjustment).

Spring Plate Free Play Adjustment

NOTE

○The free play adjustment is performed by replacing the steel plate(s).

•Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the steel plate(s) which brings the free play within the usable range.

Spring Plate Free Play
Usable Range:	0.05 0.70 mm (0.002 0.028 in.)

○
Replace the following steel plate(s).
Thickness		Part Number
2.3 mm (0.090 in.)		13089-0008
2.6 mm (0.102 in.) (STD)		13089-0009
2.9 mm (0.114 in.)		13089-1093

NOTE

○Do not use the steel plate of 2.3 mm (0.090 in.) and 2.9 mm (0.114 in.) thickness at the same time.

CLUTCH 6-17

Clutch

Clutch Plate Assembly Length (Reference Information)

•Assemble the following parts. Clutch Hub [A]

Spring Seat [B] Spring [C]

Sub Clutch Hub [D]

Sub Clutch Hub Bolts [E] New Friction Plates [F] Steel Plates [G]

Spring Plate [H]

Clutch Springs [I]

Clutch Spring Holders [J] Clutch Spring Bolts [K]

Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•Measure the clutch plate assembly length [L].

Clutch Plate Assembly Length (Reference)

40.6 mm (1.60 in.)

NOTE

○The length of the clutch plate assembly changes by the steel plate thickness.

Clutch Plate, Wear, Damage Inspection

•Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear.

•Measure the thickness of each friction plate [A] at several points.

If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.

Friction Plate Thickness

Standard: 2.72 2.88 mm (0.107 0.113 in.)

Service Limit: 2.5 mm (0.098 in.)

Clutch Plate Warp Inspection

•Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with a new one.

Friction and Steel Plate Warp

Standard:	0.15 mm (0.0059 in.) or less
Service Limit:	0.3 mm (0.012 in.)

6-18 CLUTCH

Clutch

Clutch Spring Free Length Measurement

•Measure the free length of the clutch springs [A].

If any spring is shorter than the service limit, it must be replaced.

Clutch Spring Free Length
Standard:	41.6 mm (1.64 in.)
Service Limit:	40.1 mm	(1.58 in.)

Clutch Housing Finger Inspection

•Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them.

If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.

Clutch Housing Spline Inspection

•Visually inspect where the teeth [A] on the steel plates wear against the sub clutch hub splines [B].

If there are notches worn into the splines, replace the sub clutch hub. Also, replace the steel plates if their teeth are damaged.

Damper Cam Inspection

•Remove the clutch (see Clutch Removal).

•Visually inspect the damper cam [A], cam follower [B], and the torque limiter spring [C].

•Replace the part if it appears damaged.