Removal
Remove the right crankcase cover (page 10-13).
Loosen the lifter plate bolts in a crisscross pattern in two or three steps, and remove the bolts and clutch springs.
Remove the lifter plate.
Remove the lifter piece and clutch lifter rod.
Remove the clutch discs and plates.
Unstake the clutch center lock nut.
Be careful not to damage the main-shaft threads.
Hold the clutch center with the clutch center holder, then loosen and remove the lock nut.
Tools:
- Holder plate — 07HGB-001010B or 07HGB-001010A and
- Holder collar "A" — 07HGB-001020B or 07HGB-001020A
Discard the lock nut.
Remove the washer.
Remove the clutch center.
Remove the thrust washer, clutch outer and needle bearing.
Remove the oil pump driven sprocket bolt/washer.
Remove the oil pump drive sprocket, driven sprocket and drive chain as an assembly.
Remove the clutch outer guide.
Inspection
Clutch lifter bearing
Turn the inner race of the lifter bearing with your finger.
The bearing should turn smoothly and freely without excessive play.
If necessary replace the bearing.
Remove the bearing from the lifter plate.
Drive in the bearing to the lifter plate using the special tools.
Tools:
- Driver — 07743-0010000
- Attachment, 32 x 35 mm — 07746-0010100
- Pilot, 17 mm — 07746-0040400
Clutch spring
Measure the clutch spring free length.
Service limit: 56.7 mm (2.23 in).
Replace the clutch springs as a set.
Clutch center
Check the grooves of the clutch center for damage or wear caused by the clutch plates.
Replace if necessary.
Clutch lifter rod
Check the clutch lifter rod for bending or damage.
Clutch disc
Check the clutch discs for signs of scoring or discoloration.
Measure the clutch disc thickness.
Service limit: 3.1 mm (0.12 in).
Replace the clutch discs and plates as a set.
Clutch plate
Check the clutch plate for discoloration.
Check the clutch plate warpage on a surface plate using a feeler gauge.
Service limit: 0.30 mm (0.012 in).
Replace the clutch discs and plates as a set.
Clutch outer guide
Measure the clutch outer guide I.D.
Service limit: 28.8 mm (1.106 in).
Mainshaft
Measure the mainshaft O.D. at the clutch outer guide.
Service limit: 27.970 mm (1.1012 in).
Clutch outer
Check the slots in the clutch outer for nicks, indentations or abnormal wear caused by the clutch discs.
Check the clutch outer needle bearing for wear or damage.
Replace the bearing if necessary.
Oil pump drive chain slider
Inspect oil pump drive chain slider for excessive wear or damage.
Remove the bolts and replace if necessary.
Installation
Coat the clutch outer guide with molybdenum oil solution and install it onto the mainshaft with the flange side facing the crankcase.
Install the oil pump drive sprocket, driven sprocket and drive chain as an assembly.
Install the driven sprocket with its "OUT" mark facing out.
Align the cut-outs on the driven sprocket and the oil pump shaft.
Apply a locking agent to the threads of the oil pump driven sprocket bolt and install the washer and bolt.
Tighten the driven sprocket bolt to the specified torque after installing the clutch outer.
Apply molybdenum oil solution to the needle bearing. Install the needle bearing to the mainshaft.
Install the clutch outer aligning the holes on the clutch outer with the bosses on the oil pump drive sprocket by turning the oil pump driven sprocket with your finger.
Tighten the oil pump driven sprocket bolt to the specified torque.
Torque: 18 N·m (1.8 kgf·m, 13 lbf·ft).
Install the thrust washer.
Install the clutch center.
Install the washer with its "OUT" mark facing out.
Apply engine oil to the threads and seating surface of a new clutch center lock nut and install it onto the mainshaft.
Hold the clutch center with the clutch center holder, then tighten the lock nut to the specified torque.
Tools:
- Holder plate — 07HGB-001010B or 07HGB-001010A and
- Holder collar "A" — 07HGB-001020B or 07HGB-001020A
Torque: 186 N·m (19.0 kgf·m, 137 lbf·ft).
Stake the clutch center lock nut into the mainshaft groove.
Be careful not to damage the main-shaft threads.
Coat the clutch discs with clean engine oil.
Install the eight clutch discs and seven clutch plates alternately, starting with a clutch disc.
Install the tabs of the outer clutch disc into the shallow slots of the clutch outer.
Install the clutch lifter rod into the mainshaft.
Coat the clutch lifter piece with molybdenum oil solution and install it into the mainshaft.
Install the clutch lifter plate, clutch springs and clutch pressure plate bolts.
Tighten the lifter plate bolts in a crisscross pattern in several steps.
Torque: 12 N·m (1.2 kgf·m, 9 lbf·ft).
Install the right crankcase cover (page 10-14).