General
This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame.
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the clutch reservoir is horizontal.
Never allow contaminates (e.g., dirt, water) to get into an open reservoir.
Once the hydraulic system has been opened, or if the clutch lever feels spongy, the system must be bled.
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid, they may not be compatible.
Engine oil viscosity, level and the use of oil additives have an effect on clutch disengagement. Oil additives of any kind are specifically not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch disengaged, inspect the engine oil viscosity and level before servicing the clutch system.
The crankcase must be separated when the transmission, shift drum and shift forks require service (section 11).
Specification
| ITEM | STANDARD | SERVICE LIMIT | |
| Recommended clutch fluid | DOT 4 brake fluid | — | |
| Clutch master cylinder | Cylinder I.D. | 12.700 - 12.743 (0.5000 - 0.5017) | 12.76 (0.502) |
| Piston O.D. | 12.657 - 12.684 (0.4983 - 0.4994) | 12.65 (0.498) | |
| Clutch | Spring free length | 58.2 (2.29) | 56.7 (2.23) |
| Disc thickness | 3.72-3.88 (0.146-0.153) | 3.1 (0.12) | |
| Plate warpage | — | 0.30 (0.012) | |
| Clutch outer guide I.D. | 27.995 - 28.012 (1.1022 - 1.1028) | 28.8 (1.106) | |
| Mainshaft O.D. at clutch outer guide | 27.980 - 27.993 (1.1016 - 1.1021) | 27.970 (1.1012) | |
Torque values
| Clutch lifter plate bolt | 12 N·m (1.2 kgf·m, 9 lbf·ft) | |
| Clutch center lock nut | 186 N·m (19.0 kgf·m, 137 lbf·ft) | Stake. Apply oil to the threads and flange surface. |
| Primary drive gear bolt | 137 N·m (14.0 kgf·m, 101 lbf·ft) | Apply oil to the threads and flange surface. |
| Primary driven gear nut | 186 N·m (19.0 kgf·m, 137 lbf·ft) | Stake. Apply oil to the threads and flange surface. |
| Shift drum stopper arm bolt | 12 N·m (1.2 kgf·m, 9 lbf·ft) | |
| Shift drum center socket bolt | 23 N·m (2.3 kgf·m, 17 lbf·ft) | Apply a locking agent to the threads. |
| Shift return spring pin | 23 N·m (2.3 kgf·m, 17 lbf·ft) | |
| Change pedal pinch bolt | 12 N·m (1.2 kgf·m, 9 lbf·ft) | |
| Clutch master cylinder holder bolt | 12 N·m (1.2 kgf·m, 9 lbf·ft) | |
| Clutch master cylinder reservoir cap screw | 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) | |
| Clutch lever pivot bolt | 1 N·m (0.1 kgf·m, 0.7 lbf·ft) | |
| nut | 6 N·m (0.6 kgf·m, 4.3 lbf·ft) | |
| Clutch switch screw | 1.2 N·m (0.12 kgf·m, 0.9 lbf·ft) | |
| Clutch hose oil bolt | 34 N·m (3.5 kgf·m, 25 lbf·ft) | |
| Slave cylinder bleed valve | 6 N·m (0.6 kgf·m, 4.3 lbf·ft) | |
| Oil pump driven sprocket bolt | 18 N·m (1.8 kgf·m, 13 lbf·ft) | Apply a locking agent to the threads. |
Tools
| Gear holder | 07724-0010100 not available in U.S.A. |
| Attachment, 32 x 35 mm | 07746-0010100 |
| Pilot, 17 mm | 07746-0040400 |
| Driver | 07749-0010000 |
| Snap ring pliers | 07914-SA50001 |
| Holder plate | 07HGB-001010B or 07HGB-001010A and |
| Holder collar "A" | 07HGB-001020B or 07HGB-001020A |