CLUTCH

Removing the clutch
Order	Job/Parts to remove	Q’ty	Remarks
	Engine oil		Drain. Refer to CHANGING THE ENGINE OIL.
1	Clutch cable	1	Disconnect.
2	Clutch cover	1
3	Gasket	1
4	Pressure plate 1	1
5	Clutch spring	1
6	Spring retainer	1
7	Pressure plate 2	1
8	Circlip	1
9	Bearing	1
10	Push rod 1	1
11	Ball	1

Removing the clutch
Order	Job/Parts to remove	Q’ty	Remarks
12	Clutch plate 2	2	[Thickness: 1.0 mm (0.04 in)]
13	Friction plate 2	4	Blue paint on the outer circumference of the pawls.
14	Clutch plate 1	7	[Thickness: 1.4 mm (0.06 in)]
15	Friction plate 1	4
16	Collar	6
17	Washer	1
18	Sleeve	1
19	Absorber	6
20	Clutch boss	1
21	Washer	1
22	Primary driven gear	1
23	Collar	1
24	Idle gear	1
25	Washer	1

Removing the crankcase cover (right)
Order	Job/Parts to remove	Q’ty	Remarks
	Right engine guard		Refer to ENGINE REMOVAL.
	Engine oil		Drain. Refer to CHANGING THE ENGINE OIL.
	Coolant		Drain. Refer to CHANGING THE COOLANT.
	Brake pedal		Refer to ENGINE REMOVAL.
	Clutch cover		Refer to CLUTCH.
1	Oil filter element cover	1
2	Oil filter element	1
3	Oil filler cap	1
4	Crankcase cover (right)	1
5	Gasket	1
6	Dowel pin	2

Removing the clutch release
Order	Job/Parts to remove	Q’ty	Remarks
	Drive sprocket cover		Refer to CHAIN DRIVE.
1	Push lever shaft	1
2	Clutch release	1
3	Oil seal	1
4	Bearing	2
5	Push rod 2	1
6	Oil seal	1

REMOVING THE CLUTCH

1.Straighten the clutch boss nut rib “a”.

2.Remove:

Clutch boss nut “1”
Washer “2”
Sleeve “3”
Absorber
Clutch boss

: While holding the sleeve with the clutch holder “4”, loosen the clutch boss nut.

Clutch holder

90890-04199
Universal clutch holder

YM-91042

CHECKING THE FRICTION PLATES

1.Check:

Friction plate

Damage/wear → Replace the friction plates as a set.

2.Measure:

Friction plate thickness

Out of specification → Replace the friction plates as a set.

: Measure it at four points on the friction plate.

Friction plate 1 thickness

2.12–2.28 mm (0.083–0.090 in)
Wear limit

2.02 mm (0.080 in)
Friction plate 2 thickness

2.12–2.28 mm (0.083–0.090 in)
Wear limit

2.02 mm (0.080 in)

CHECKING THE CLUTCH PLATES

1.Check:

Clutch plate

Damage → Replace the clutch plates as a set.

2.Measure:

Clutch plate warpage

(with a surface plate and thickness gauge)

Out of specification → Replace the clutch plates as a set.

Thickness gauge

90890-03268
Feeler gauge set

YU-26900-9

Warpage limit

0.10 mm (0.004 in)

CHECKING THE CLUTCH SPRING

1.Check:

Pressure plate

Damage → Replace.

2.Check:

Spring retainer

Damage → Replace.

3.Check:

Clutch spring

Damage → Replace the clutch spring.

4.Measure:

Clutch spring free height

Out of specification → Replace the clutch spring.

Clutch spring free height

5.80 mm (0.228 in)
Clutch spring free height limit

5.51 mm (0.217 in)

CHECKING THE COLLAR

1.Check:

Collar “1”

Damage/pitting/wear → Replace the collars as a set.

: Pitting on the collar will cause erratic clutch operation.

CHECKING THE PRESSURE PLATE

1.Check:

Pressure plate

Crack/damage → Replace.

CHECKING THE PUSH LEVER SHAFT

1.Check:

Push lever shaft

Wear/damage → Replace.

CHECKING THE PUSH ROD

1.Check:

Push rod 1 “1”
Bearing “2”
Ball “3”
Push rod 2 “4”

Cracks/damage/wear → Replace.

2.Measure:

Push rod 2 bending limit

Out of specification → Replace.

Push rod bending limit

0.10 mm (0.004 in)

CHECKING THE PRIMARY DRIVE GEAR

1.Check:

Primary drive gear

Damage/wear → Replace the primary drive and primary driven gears as a set.

Excessive noise during operation → Replace the primary drive and primary driven gears as a set.

2.Check:

Primary-drive-gear-to-primary-driven-gear free play

Free play exists → Replace the primary drive and primary driven gears as a set.

CHECKING THE PRIMARY DRIVEN GEAR

1.Check:

Primary driven gear

Damage/wear → Replace the primary drive and primary driven gears as a set.

Excessive noise during operation → Replace the primary drive and primary driven gears as a set.

2.Check:

Primary driven gear dogs “1”

Damage/pitting/wear → Deburr the primary driven gear dogs or replace the primary driven gear.

: Pitting on the primary driven gear dogs will cause erratic clutch operation.

ASSEMBLING THE CLUTCH RELEASE

1.Install:

Bearing “1”
Oil seal “2”

Installed depth “a”

25.3–25.8 mm (1.00–1.02 in)
Installed depth “b”

5.5–6.0 mm (0.22–0.24 in)
Installed depth “c”

0.1–0.6 mm (0.004–0.024 in)

Apply engine oil on the bearings.
Apply lithium-soap-based grease on oil seal.

INSTALLING THE CLUTCH RELEASE

1.Install:

Oil seal “1”

Installed depth “a”

0.0–0.5 mm (0.00–0.02 in)

2.Install:

Push rod 2 “1”
Washer “2”
O-ring “3”
Clutch release “4”

Bolt (clutch release)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

LOCTITE®

: Apply lithium-soap-based grease on the O-ring and the seal lip.

INSTALLING THE CLUTCH

1.Install:

Oil seal “1”
Circlip “2”
Check ball seat “3”

Apply the lithium-soap-based grease on the oil seal lip.
Install the oil seal in parallel with its manufacture’s marks or numbers facing inward.

Installed depth “a”

0 mm (0 in)

2.Install:

Dowel pin “1”
Gasket “2”

3.Install:

Crankcase cover (right) “1”
Crankcase cover bolt (right) “2”

Crankcase cover bolt (right)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

: Tighten the crankcase cover bolts (right) in stages and in a crisscross pattern.

4.Install:

Push lever shaft “1”

Apply the lithium-soap-based grease on the oil seal lip.
Before installation, apply the engine oil to the bearings (upper side and lower side).

5.Install:

Washer “1”
Idle gear “2”
Collar “3”
Primary driven gear “4”
Washer “5”
Clutch boss “6”
Absorber “7”
Sleeve “8”
Washer “9”
Clutch boss nut “10”

6.Tighten:

Clutch boss nut “1”

Clutch boss nut

105 N·m (10.5 kgf·m, 77 lb·ft)

LOCTITE®

: Make sure to tighten to specification; otherwise, it may damage the other part that is fastened together.

Use the clutch holder “2” to hold the sleeve.
Stake the clutch boss nut at cutouts “a” in the main axle.

Clutch holder

90890-04199
Universal clutch holder

YM-91042

7.Install:

Collar “1”
Clutch plate 2 (thickness: 1.0 mm (0.04 in)) “2”
Friction plate 2 (painted) “3”
Clutch plate 1 (thickness: 1.4 mm (0.06 in)) “4”
Friction plate 1 (unpainted) “5”

Friction plate 2 that have blue paint on the outer circumference of the pawls.
Install the clutch plates and friction plates alternately on the sleeve, starting with a clutch plate and ending with a clutch plate.
From the clutch boss side, install the friction plates and clutch plates in the order of the illustrations.
Apply the engine oil on the collars, friction plates, and clutch plates.

8.Install:

Bearing “1”
Circlip “2”

(to the push rod 1 “3”)

: Apply the engine oil on the bearing and push rod 1.

9.Install:

Ball “1”
Push rod 1 “2”

: Apply the engine oil on the push rod 1 and ball.

10.Install:

Pressure plate 2 “1”

11.Install:

Spring retainer “1”
Clutch spring “2”
Pressure plate 1 “3”
Bolt (pressure plate 1) “4”

Bolt (pressure plate 1)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

Apply the engine oil on the threads and contact surface of the bolts, and contact surface of the pressure plate 1.
First temporarily tighten all bolts to 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) in a crisscross pattern. Then retighten them to 10 N·m (1.0 kgf·m, 7.4 lb·ft) in a crisscross pattern.

A.	Engine side

12.Install:

Gasket “1”
Clutch cover “2”
Clutch cover bolt (long) “3”
Clutch cover bolt (short) “4”

Clutch cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)

: Tighten the bolts in stages and in a crisscross pattern.