CLUTCH

Removing the clutch

Order

Job/Parts to remove

Q’ty

Remarks

 

Engine oil

 

Drain.

Refer to CHANGING THE ENGINE OIL.

 

Brake pedal

 

Refer to ENGINE REMOVAL.

1

Clutch cable

1

Disconnect.

2

Clutch cover

1

 

3

Gasket

1

 

4

Clutch spring

6

 

5

Pressure plate

1

 

6

Push rod 1

1

 

7

Circlip

1

 

8

Bearing

1

 

9

Ball

1

 

10

Push rod 2

1

 

Removing the clutch

Order

Job/Parts to remove

Q’ty

Remarks

11

Friction plate 1

2

Identification color (black)

12

Clutch plate

7

 

13

Friction plate 2

6

Identification color (orange)

14

Clutch boss

1

 

15

Thrust washer

1

 

16

Primary driven gear

1

 

17

Push lever shaft

1

 

Removing the crankcase cover (right)

Order

Job/Parts to remove

Q’ty

Remarks

 

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

Radiator pipe 2

1

 

4

Crankcase cover (right)

1

 

5

Gasket

1

 

6

Dowel pin

2

 

REMOVING THE CLUTCH

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

2.Remove:

  • Clutch boss nut “1”

  • Conical washer “2”

  • Clutch boss “3”

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

  • Do not use an impact wrench for removing 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

    2.70–2.90 mm (0.106–0.114 in)

  • Wear limit

    2.60 mm (0.102 in)

  • Friction plate 2 thickness

    2.72–2.88 mm (0.107–0.113 in)

  • Wear limit

    2.62 mm (0.103 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

  • Clutch plate thickness

    1.50–1.70 mm (0.059–0.067 in)

  • Warpage limit

    0.10 mm (0.004 in)

CHECKING THE CLUTCH SPRINGS

1.Check:

  • Clutch spring

    Damage → Replace the clutch springs as a set.

2.Measure:

  • Clutch spring free length

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

  • Clutch spring free length

    44.50 mm (1.75 in)

  • Clutch spring free length limit

    42.28 mm (1.66 in)

CHECKING THE CLUTCH HOUSING

1.Check:

  • Clutch housing dogs “1”

    Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause erratic clutch operation.

CHECKING THE CLUTCH BOSS

1.Check:

  • Clutch boss splines

    Damage/pitting/wear → Replace the clutch boss.

Pitting on the clutch boss splines 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 RODS

1.Check:

  • Push rod 1 “1”

  • Bearing/Washer “2”

  • Push rod 2 “3”

  • Ball “4”

    Cracks/damage/wear → Replace.

2.Measure:

  • Push rod 2 bending limit

    Out of specification → Replace.

  • Push rod bending limit

    0.30 mm (0.012 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.

INSTALLING THE CLUTCH

1.Install:

  • Dowel pin “1”

  • Gasket “2”

2.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.

3.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).

4.Install:

  • Primary driven gear “1”

  • Thrust washer “2”

  • Clutch boss “3”

  • Washer “4”

Apply the engine oil on the primary driven gear inner circumference.

5.Install:

  • Conical washer “1”

  • Clutch boss nut “2”

  • Clutch boss nut

    95 N·m (9.5 kgf·m, 70 lb·ft)

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

  • Install the conical washer on the main axle with the “OUT” mark “a” facing away from the vehicle.

  • Apply engine oil to the threads and contact surface of the clutch boss nut.

  • Apply engine oil to the contact surfaces of the conical washer.

  • Use the clutch holder “3” to hold the clutch boss.

  • Do not use an impact wrench for installing the clutch boss nut.

  • Stake the clutch boss nut at cutouts “b” in the main axle.

  • Clutch holder

    90890-04199

  • Universal clutch holder

    YM-91042

6.Install:

  • Friction plate 1 “1”

  • Clutch plate “2”

  • Friction plate 2 “3”

  • Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.

  • From the clutch boss side, install the friction plates in order: friction plate 1 (identification color: black) × 1, friction plate 2 (identification color: orange) × 6, and friction plate 1 (identification color: black) × 1.

  • Apply the engine oil on the friction plates and clutch plates.

a.

Identification color

7.Install:

  • Bearing “1”

  • Washer “2”

  • Circlip “3”

    (to the push rod 1 “4”)

Apply the engine oil on the bearing, washer and push rod 1.

8.Install:

  • Push rod 2 “1”

  • Ball “2”

  • Push rod 1 “3”

Apply the engine oil on the push rod 1, 2 and ball.

9.Install:

  • Pressure plate “1”

Making sure to align a “a” on the pressure plate with the punch mark “b” on the clutch housing.

10.Install:

  • Clutch spring

  • Clutch spring bolt

  • Clutch spring bolt

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

Tighten the bolts in stages and in a crisscross pattern.

11.Install:

  • Gasket “1”

12.Install:

  • Clutch cover

  • Clutch cover bolt

  • Clutch cover bolt

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

Tighten the bolts in stages and in a crisscross pattern.