COMPONENT LOCATION
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Ibf-ft) |
• This section covers service of the clutch, starter clutch, kickstarter and gearshift linkage. All service can be done with the engine installed in the frame.
• Transmission oil viscosity and level have an effect on clutch disengagement. Oil additives also affect clutch performance and are not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch pulled in, inspect the transmission oil level before servicing the clutch system.
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Unit: mm (in |
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ITEM |
STANDARD |
SERVICE LIMIT |
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Clutch lever freeplay |
10-20(3/8- 13/16) |
- |
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Clutch spring free length |
44.7 (1.76) |
43.7 (1.72) |
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Clutch disc thickness |
2.92 - 3.08 (0.115 - 0.121) |
2.85 (0.112) |
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Clutch plate warpage |
- |
0.15 (0.006) |
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Kickstarter pinion gear I. D. |
22.007 - 22.028 (0.8664 - 0.8672) |
22.05 (0.868) |
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Kickstarter pinion gear bushing |
I. D. |
20.000-20.021 (0.7874-0.7882) |
20.04 (0.789) |
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O. D. |
21.979 - 22.000 (0.8653 - 0.8661) |
21.96 (0.865) |
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Kickstarter spindle O. D. |
19.980 - 19.993 (0.7866 - 0.7871) |
19.97 (0.786) |
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Kickstarter idle gear I D. |
20.020 - 20.041 (0.7882 - 0.7890) |
20.07 (0.790) |
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Kickstarter idle gear bushing |
I. D. |
17.000 - 17.018 (0.6693 - 0.6700) |
17.04 (0.671) |
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O. D. |
19.979 - 20.000 (0.7866 - 0.7874) |
19.96 (0.786) |
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Countershaft O. D. at kickstarter idle gear |
16.966 - 16.984 (0.6680 - 0.6687) |
16.95 (0.667) |
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Starter driven gear boss |
I. D. |
36.009 - 36.034 (1.4177 - 1.4187) |
36.034 (1.4187) |
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O. D. |
45.660 - 45.673 (1.7976 - 1.7981) |
45.660(1.7976) |
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Reduction gear A I. D. |
12.010 - 12.050 (0.4728 - 0.4744) |
12.050 (0.4744) |
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Reduction gear В I. D. |
10.045 - 10.085 (0.3955 - 0.3970) |
10.085 (0.3970) |
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Idle gear I. D. |
12.010 - 12.050 (0.4728 - 0.4744) |
12.050 (0.4744) |
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Gear holder shafts O. D. |
11.989- 12.000(0.4720-0.4724) |
11.989 (0.4720) |
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Reduction gear shaft O. D. |
9.980 - 9.995 (0.3929 - 0.3935) |
9.980 (0.3929) |
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80 N m (8.2 12 N m (1.2 22 N m (2.2 12 N m (1.2 38 N m (3.9 12 N m (1.2 22 N m (2.2 108 N-m (11 18 N-m (1.8 |
Clutch center lock nut Clutch spring bolt Gearshift drum center pin Gearshift drum stopper arm bolt Kickstarter pedal bolt Gearshift pedal pinch bolt Gearshift return spring pin Primary drive gear bolt Starter gear holder mounting bolt
kgf-m, 59 lbf-ft) kgf-m, 9 lbf-ft) kgf-m, 16 lbf-ft) kgf-m, 9 lbf-ft) kgf-m, 28 lbf-ft) kgf-m, 9 lbf-ft) kgf-m, 16 lbf-ft)
.0 kgf-m, 80 lbf-ft) kgf-m, 13 lbf-ft)
Apply oil to the threads and seating surface Apply locking agent to the threads
Apply oil to the threads Apply oil to the threads
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L |
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Hard to shift
• Improper clutch operation
• Improper oil viscosity
• Incorrect clutch adjustment
• Loose stopper plate bolt
• Damaged stopper plate and pin
• Damaged gearshift spindle
• Bent shift fork (page 13-13)
• Bent shift fork shaft (page 13-13)
• Bent fork claw (page 13-13)
Transmission jumps out of gear
• Worn shift drum stopper arm
• Weak or broken shift arm return spring
• Loose stopper plate bolt
• Bent shift fork shaft (page 13-13)
• Damaged or bent shift fork (page 13-13)
• Damaged shift drum center groove
• Faulty ratchet pawl
• Worn gear engagement dogs or slot (page 13-12)
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
• Bent gearshift spindle
Clutch slips when accelerating
• Incorrect clutch adjustment
• Worn clutch discs
• Weak clutch springs
• Transmission oil mixed with molybdenum or graphite additives
Motorcycle creeps with the engine idling
• Incorrect clutch adjustment
• Clutch plate warped
• Faulty clutch lifter
• Incorrect transmission oil
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged or faulty starter motor pinion gear, reduction gears, idle gear or starter driven gear.
