Disassembly
1. Remove the rider's seat (see page 16-13).
2. Disconnect the battery, negative (black) lead first.
3. Release the clutch cable from the actuating arm (see page 4-5).
4. Remove the clutch cover. Discard the clutch cover gasket.
1. Clutch cover
5. Undo the bolts and remove the springs and clutch pressure plate.
6. Remove the clutch pull-rod.
1. Clutch pull-rod; 2. Clutch pressure plate
7. Remove the clutch friction plates and steel plates together with the anti-judder spring and anti-judder seat washer.
Note: Record the orientation of all components as they are removed. The plates must be assembled in the same order.
1. Steel plate; 2. Inner fiction plate; 3. Anti-judder spring; 4. Anti-judder seat washer; 5. Clutch inner drum
Note:
- The inner and outermost friction plates are different to the remainder and are also different to each other. They must be fitted in their noted positions.
- The three outer steel plates may be different to the other plates, depending on the clutch pack height settings used during manufacture
4-8>. They must be fitted in their noted positions. - Store all plates in their correct fitted order to avoid confusion on installation.
- Refer to the following page of this section for details of clutch friction plate checking.
- lt is not normally necessary to disassemble the clutch further, but if the clutch inner and outer drums are to be removed, proceed as follows:
8. Engage second gear and lock the inner and outer clutch drums together using service tool T3880306.
1. Service Tool T3880306
9. Depress the rear brake pedal to prevent the engine from turning, then release the clutch centre nut.
10. Remove the centre nut (discard the nut), Belleville washer, flat washer, clutch inner drum and thrust washer.
1. Centre nut; 2. Belleville washer; 3. Flat washer; 4. Inner drum; 5. Thrust washer
11. Slide the clutch outer drum assembly gently backwards and forwards to dislodge the inner bearing sleeve. Carefully remove the bearing sleeve while supporting the clutch drum.
1. Outer drum; 2. Bearing sleeve
12. Remove the clutch outer drum leaving the oil pump drive sprocket, bearing and sleeve in place on the input shaft.