7. CLUTCH/GEARSHIFT LINKAGE

Page 7-0

Page 7-1

SERVICE INFORMATION

GENERAL

This section covers the removal and installation of the clutch, oil pump drive chain, gearshift linkage and primary drive gear. All these operations can be done with the engine installed in the frame.
If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 11).
Coat the new clutch disks with clean engine oil before reassembly.

SPECIFICATIONS

Unit: mm (in)

ITEM STANDARD SERVICE LIMIT
Clutch Spring free length 44.4 (1.75) 42.8 (1.69)
Spring preload/length 22.75/26.2 kg/mm
(50.15/1.031 lb/in) ---
Disk Thickness Disk A 2.92-3.08 (0.115-0.121) 2.60 (0.102)
Disk B 2.62-2.78 (0.103-0.109) 2.30 (0.091)
Plate Warpage --- 0.30 (0.012)
Outer guide I.D. 21.991-22.016 (0.8658-0.8668) 22.09 (0.870)
O.D. 31.959-31.975 (1.2582-1.2589) 31.92 (1.257)
Outer I.D. 32.000-32.025 (1.2598-1.2608) 32.10 (1.264)
Oil pump drive sprocked I.D. 32.000-32.025 (1.2598-1.2608) 32.10 (1.264)
Mainshaft O.D at clutch outer guide 21.967-21.980 (0.8648-0.8654) 21.92 (0.863)

ITEM	STANDARD	SERVICE LIMIT
Clutch	Spring free length	44.4 (1.75)	42.8 (1.69)
Spring preload/length	22.75/26.2 kg/mm (50.15/1.031 lb/in)	---
Disk Thickness	Disk A	2.92-3.08 (0.115-0.121)	2.60 (0.102)
Disk B	2.62-2.78 (0.103-0.109)	2.30 (0.091)
Plate Warpage	---	0.30 (0.012)
Outer guide	I.D.	21.991-22.016 (0.8658-0.8668)	22.09 (0.870)
O.D.	31.959-31.975 (1.2582-1.2589)	31.92 (1.257)
Outer I.D.	32.000-32.025 (1.2598-1.2608)	32.10 (1.264)
Oil pump drive sprocked I.D.	32.000-32.025 (1.2598-1.2608)	32.10 (1.264)
Mainshaft O.D at clutch outer guide	21.967-21.980 (0.8648-0.8654)	21.92 (0.863)

TORQUE VALUES

Shift drum stopper plate bolt	26 N.m (2.6 kg-m, 19 ft-lb) Apply locking agent to the threads
Primary drive gear bolt	90 N.m (9.0 kg-m, 65 ft-lb)
Oil pump driven sprocket bolt	15 N.m (1.5 kg-m, 11 ft-lb) Apply locking agent to the threads
Cluch lock nut	130 N.m (13.0 kg-m, 94 ft-lb) Staked nut
Oil pass pipe bolt (8mm) (7mm)	23 N.m (2.3 kg-m, 17 ft-lb) 10 N.m (1.0 kg-m, 7.2 ft-lb)

Page 7-3

RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil (page 2-3).
Remove the exhaust pipe.
Remove the clutch cable holder and disconnect the clutch cable from the clutch lifter arm.
Loosen the oil pipe holder and remove the oil pipe bolt and sealing washers from the right crankcase cover.

Remove the right crankcase cover bolts and cover.

NOTE

R. crankcase cover can be serviced with rear exhaust pipe removal only.

Remove the dowel pins and gasket.

Remove the oil orifice.

CLUTCH LIFTER

Remove the clutch lifter piece, and remove the snap ring and return spring from the right crankcase cover.

Remove the clutch lifter shaft.

Check the clutch lifter piece and shaft for damage or excessive scratching.
Check the return spring for fatigue or damage.

Page 7-4

Check the needle bearings for wear or damage or a loose fit in the cover.
Check the dust seal for fatigue or damage.

Apply grease to the dust seal and needle bearing.

Install the clutch lifter shaft, snap ring and return spring.
Hook the spring end in the cover tab securely, and turn the shaft.

Install the clutch lifter piece, aligning the piece end with the groove in the clutch lifter shaft.

CLUTCH REMOVAL

Remove the following:

clutch bolts
clutch lifter plate
springs

NOTE

Remove the bolts in a crisscross pattern in 2 or 3 steps.

Unstake the clutch lock nut with a drill or grinder. NOTE

Be careful not to damage the shaft threads.

Page 7-5

Hold the clutch center with the special tool and loosen the clutch lock nut. Remove the tools and the lock nut.

TOOLS:


Clutch center holder           07923-KE10000 or
                               07HGB-001000A
                               (U.S.A. only)
Lock nut wrench, 17 x 27 mm    07716-0020300 
                               Equivalent commercially 
                               available in U.S.A.

Hint:

A conventional 27mm socket works as a lock nut wrench.

NOTE

If you will remove the oil pump driven sprocket, loosen the driven sprocket mounting bolt at this time.

Remove the following:

washer
clutch center, judder spring and spring seat
discs and plates pressure plate

Remove the thrust washer and clutch outer.

Remove the oil pump driven sprocket mounting bolt, driven sprocket and oil pump drive chain.

Page 7-6

Remove the drive sprocket and clutch outer guide from the mainshaft.

INSPECTION

Check the lifter plate bearing for damage.
Turn the bearing inner race with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the clutch lifter plate.
Replace the bearing if necessary.

Measure the spring free length.

SERVICE LIMIT: 42.8 mm (1.69 in)

Info:

The standard length is 44.4 mm (1.75 in).

Replace the clutch discs if they show signs of scoring or discoloration.

Measure the thickness of discs A and B.

SERVICE LIMITS:
Disc A: 2.60 mm (0.102 in)
Disc B: 2.30 mm (0.091 in)

NOTE

Replace the discs and plates as a set if any one is beyond the service limit.

Page 7-7

Check the plate warpage on a surface plate using a thickness gauge.

SERVICE LIMIT: 0.30 mm (0.012 in)

NOTE

Replace the discs and plates as a set if any one is beyond the service limit.

Check the clutch center for nicks or indentations made by the clutch plates.

Check the spring seat and judder spring for distortion, wear or damage.
Replace them if necessary.

Check the slots in the clutch outer for nicks or indentations made by the clutch discs.

Measure the l.D. of the clutch outer.

SERVICE LIMIT:
Clutch outer l.D. 32.10 mm (1.264 in)

Page 7-8

Check the oil pump drive sprocket for damage.

Measure l.D of the drive sprocket and the O.D. and l.D. of the
outer guide.

SERVICE LIMITS:

Oil pump drive sprocket l.D.   32.10 mm (1.264 in)
Clutch outer guide O.D.   31.92 mm (1.257 in)
I.D.   22.09 mm (0.870 in)

Measure the mainshaft O.D. at the clutch outer guide.

SERVICE LIMIT: 21.92 mm (0.863 in)

GEARSHIFT LINKAGE

REMOVAL

Remove the following:

drive sprocket cover (page 8-2)
gearshift pedal arm from the gearshift spindle
right crankcase cover (page 7-3)
clutch assembly (page 7-4)
oil pump drive chain (page 7-5)

Loosen the two oil pipe stay mounting bolts and remove the oil
pipe mounting bolt.

Pull the oil pipe out of the stay and oil pump.

Page 7-9

Remove the following:

gearshift spindle
drum stopper arm bolt, stopper arm, collar and spring
drum stopper plate bolt and stopper plate/drum

INSPECTION

Check the gearshift spindle for bending or damage.
Check the return spring for fatigue or damage.

INSTALLATION

Install the collar, spring, stopper arm,
washer and stopper arm bolt and tighten the bolt.

Install the dowel pins into the holes of the gearshift drum.

Lift up the drum stopper arm and install the drum stopper plate.

Apply locking agent to the threads of the stopper plate bolt and tighten the bolt.

TORQUE: 26 N.m (2.6 kg-m, 19 ft-lb)

Install the gearshift spindle, aligning the return spring ends with the pin in the case.

Page 7-10

Install the oil pipe with a new O-ring onto the oil pipe stay and oil pump.

Tighten the bolts securely.

Install the removed parts in the reverse order of removal.

Install the gearshift arm to the gearshift spindle.

Align the punch mark on the arm with the punch mark on the spindle.

Tighten the gearshift arm pinch bolt.

TORQUE: 12 N.m (1.2 kg-m, 9 ft-lb)

Install the drive sprocket cover.

PRIMARY DRIVE GEAR

REMOVAL

Remove the following:

right crankcase cover (page 7-3)
clutch assembly (page 7-4)

Remove the pulse generator mounting bolts and pulse generators.

Temporarily install the clutch outer, then install the gear holder as shown.

TOOL:
Gear holder 07724 - 0010100 Not available in U.S.A.

Remove the following:

primary drive gear bolt and pulse generator rotor
clutch outer and gear holder
primary drive gear

Page 7-11

INSTALLATION

Install the primary drive gear with the "OUT" mark facing out.

NOTE

The primary drive gear and pulse generator rotor will only go on in one position because of the extra wide aligning spline.

Install the pulse generator rotor.

Temporarily install the clutch outer and install the gear holder as shown. TOOL:
Gear holder 07724 - 0010100 Not available in U.S.A.

Install the washer and bolt and tighten the bolt.

TORQUE: 90 N m (9.0 kg-m, 65 ft-lb)

Remove the gear holder and clutch outer.

Install the following:

pulse generators
clutch

NOTE

If the pulse generator wire grommets were removed from the case groove, reinstall them securely.

CLUTCH INSTALLATION

Apply MoS₂ paste grease to the outside of the clutch outer guide and install the oil pump drive sprocket over the outer guide.

Page 7-12

Install the oil pump drive chain on the drive sprocket.

Install the oil pump driven sprocket with the "IN" mark facing inside.

Guide the drive chain over the sprocket.

Apply locking agent to the threads of the driven sprocket mounting bolt and tighten it with the washer to the specified torque.

TORQUE: 15 N.m (1.5 kg-m, 11 ft-lb)

Align the grooves in the clutch outer with the bosses on the oil pump drive sprocket while turning the sprocket with the chain and pushing the clutch outer onto the shaft.

Install the thrust washer onto the mainshaft.

Page 7-13

Install the pressure plate, clutch discs B, plates and disc A in the clutch outer.

NOTE

Stack the discs and plates alternately.
Coat the new clutch discs with clean engine oil.

Install the spring seat and judder spring on the clutch center as shown.
Install them in the clutch outer.

NOTE

Note the positions of the seat and disc A.

Install the washer on the mainshaft.

Hold the clutch center with the clutch center holder, and tighten the lock nut to the specified torque.

TORQUE: 130 N.m (13.0 kg-m, 94 ft-lb)

TOOLS:
Clutch center holder 07923-KE10000 or
07HGB-001000A (U.S.A. only)
Lock nut wrench, 17 x 27 mm 07716-0020300 Equivalent commercially available in U.S.A.

Stake the lock nut with a center punch.

Page 7-14

Install the clutch springs, lifter plate and bolts.
Tighten the bolts in a crisscross pattern in 2 or 3 steps.

NOTE

Make sure the pressure plate firmly pushes the discs and plates.

Install the bearing into the lifter plate.

RIGHT CRANKCASE COVER

INSTALLATION

Check the oil orifice for clogging.
Install a new O-ring on the oil orifice.
Install the oil orifice with its smaller hole facing in.

Install the dowel pins and new gasket.

Info:

Gasket part number is 11394-MV1-850, about $10.50

Tighten the right crankcase cover mounting bolts in a crisscross pattern in 2 or 3 steps and install the clutch cable holder and oil pipe holder at the same time.

Info:

TORQUE: 9 N.m (0.9 kg-m, 6.5 ft-lb)

Connect the clutch cable to the clutch lifter arm.

Tighten the oil pipe bolt with the new sealing washers.

TORQUE: 23 N.m (2.3 kg-m, 17 ft-lb)

Install the exhaust pipe.

TORQUE:
Exhaust pipe joint nut: 27 N.m (2.7 kg-m, 20 ft-lb)
Muffler band bolt: 27 N.m (2.7 kg-m, 20 ft-lb)

Fill the crankcase with engine oil (page 2-3).
Adjust the clutch lever free play (page 3-15).

Oil pump drive sprocket l.D.	32.10 mm (1.264 in)
Clutch outer guide O.D.	31.92 mm (1.257 in)
I.D.	22.09 mm (0.870 in)

TOOLS:
Clutch center holder	07923-KE10000 or 07HGB-001000A (U.S.A. only)
Lock nut wrench, 17 x 27 mm	07716-0020300 Equivalent commercially available in U.S.A.

TORQUE:
Exhaust pipe joint nut:	27 N.m (2.7 kg-m, 20 ft-lb)
Muffler band bolt:	27 N.m (2.7 kg-m, 20 ft-lb)