ANUAL SERVICE M

CLUTCH SPRING

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

CLUTCH SPRING

CLUTCH DISCS

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 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.

I

CLUTCH LIFTER/NEEDLE BEARING

Check the lifter for wear or damage.

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

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

Check the clutch outer guide for abnormal wear or damage.

NEEDLE BEARING

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 LIFTER LEVER

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.

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

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.

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.

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.

PLATES

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.

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.

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.