Clutch plate thickness
Note: Wipe off engine oil from the clutch plates with a clean rag.
- Measure the thickness of drive and driven plates with a vernier calipers. If each plate is not within the service limit or standard range, replace it with a new one.
Drive plate thickness
- Service limit (No. 1): 3.22 mm (0.127 in)
- Standard (No. 2): 1.92 - 2.08 mm (0.076 - 0.082 in)
Driven plate thickness
- Service limit (No. 2): 3.17 mm (0.125 in)
- Standard (No. 1): 2.82 - 2.98 mm (0.111 - 0.117 in)
- 09900-20102: Vernier calipers
Driven plate claw width
- Measure the claw width of driven plates with a vernier calipers.
- Replace the driven plates found to have worn down to the limit.
Driven plate claw width
- Service limit (No. 1 & No. 2): 7.16 mm (0.282 in)
- 09900-20102: Vernier calipers
Clutch plate distortion
Note: Wipe off engine oil from the clutch drive and driven plates with a clean rag.
- Measure each clutch plate for distortion with a thickness gauge and surface plate.
- Replace clutch plates which exceed the limit.
- Clutch plate distortion (drive plate No. 2 and driven plate No. 1)
- Service Limit: 0.10 mm (0.004 in)
- 09900-20803: Thickness gauge
Clutch spring free length
- Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit. Replace all the springs if any spring is not within the limit.
Clutch spring free length
- Service Limit: 48.8 mm (1.92 in)
- 09900-20102: Vernier calipers
Clutch release bearing
- Inspect the clutch release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be replaced.
- Smooth engagement and disengagement of the clutch depends on the condition of this bearing.
Clutch push rod
- Inspect the clutch push rod for damage and bend. If necessary, replace it with a new one.
Clutch push rod release ball
- Inspect the push rod release ball for damage or wear. If necessary, replace it with a new one.
Clutch sleeve hub/primary driven gear assembly
- Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one.
Caution: Do not attempt to disassemble the primary driven gear assembly. They are unserviceable.
Primary drive gear bearing
- Inspect the needle bearing for abnormal noise, wear and damage. If necessary, replace it with a new one.