Friction Plate Thickness
1. If any friction plate thickness is outside the service limit, replace the friction plates as a set.
1. Clutch friction plate
Friction plate thickness - all plates
- Standard: 3.00 mm
- Service limit: 2.80 mm
Steel Plate Bend/warp
Check all plates for bend and warp as follows:
1. Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum specified thickness between the steel plate and surface plate at several points around the plate. If the feeler gauge can be passed beneath the steel plate at any point, renew the plates as a set.
1. Friction plate; 2. Feeler gauge; 3. Surface plate
Steel plate bend/warp
- Standard up to: 0.15 mm
- Service limit: 0.20 mm
Clutch Pack Height
The clutch pack height should only be measured if the friction plates and the steel plates have been replaced.
The clutch pack height is critical for a smooth operation of the transmission and must be measured prior to installation of new clutch plates.
If used clutch plates are being re-fitted, the clutch pack height measurement is not necessary, as the plates may not be worn to the service limit (and are therefore still serviceable), but could fall outside of the clutch pack height tolerance on page 4.9 when measured.
If building a new clutch pack its height must be correct. To achieve this, build the new clutch pack with the following:
- 1 x new outer friction plate;
- 7 x new friction plates;
- 1 x new inner friction plate;
- 6 x steel plates, 2.0 mm thick;
- 2 x steel plate, 1.6 mm thick.
1. Arrange the new friction and new steel plates in a stack as shown below.
Friction Plate and Steel Plate Arrangement
Clutch outer: 1. Outer friction plate; 2. Friction plates; 3. Inner friction plate; 4. Steel plate, 2.0 mm thickness; 5. Steel plate, 1.6 mm thickness
2. Place the assembled clutch pack on a flat surface and measure its height as shown below.
1. Clutch pack height
3. The correct clutch pack height for this clutch assembly is shown in the table below.
| Standard height in mm | Tolerance in mm |
| 42.20 | +0.34/-0.66 |
4. If the clutch pack height measurement is incorrect, proceed as described below/opposite:
Clutch Pack Height Too High
Note: No more than three 1.6 mm thick steel plates are to be used in the clutch pack.
1. Replace the 2.0 mm steel plate next to the 1.6 mm steel plate (indicated below) with a new 1.6 mm steel plate.
Clutch outer:
1. 2.0 mm steel plate to be replaced; 2. 1.6 mm steel plates
2. Re-check the clutch pack height as described earlier.
Clutch Pack Height Too Low
Note: At least one 1.6 mm steel plate must be in the clutch pack.
1. If the clutch pack height is too low, replace the 1.6 mm steel plate indicated below with a new 2.0 mm steel plate.
Clutch outer: 1. 1.6 mm steel plate to be replaced
2. Re-check the clutch pack height as described earlier.
Assembly
1. To fully engage the outer drum, insert a suitable tool to preload and align the primary gear and backlash eliminator gear through the hole shown in the illustration below.
1. Alignment hole; 2. Outer drum
2. Position the clutch outer drum assembly to the input shaft and align the oil pump drive pegs with the corresponding holes in the rear of the clutch outer drum.
1. Clutch outer drum; 2. Oil pump sprocket drive pegs; 3. Oil pump drive holes
3. While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive, refit the bearing sleeve and bearing.
1. Outer drum; 2. Bearing sleeve
Note: When the bearing sleeve is correctly fitted, it will be a flush fit with the clutch drum face.
4. Fit the thrust washer to the shaft.
5. Fit the clutch inner drum.
6. Fit the flat washer, a new Belleville washer ('OUT' mark facing outwards), and refit the centre nut.
Belleville Washer 'OUT' Mark
7. Lock the inner and outer drums together using service tool T3880306. Depress the rear brake pedal to prevent the engine from turning, and tighten the clutch centre nut to 98 Nm. Remove the service tool.
8. Using a suitable pin punch, stake the nut to the shaft.
1. Service tool T3880306
9. Disengage second gear and check for free rotation of the clutch inner drum.
10. Coat all clutch friction plates in clean engine oil before fitting the friction plates, steel plates, anti-judder spring and anti-judder seat washer to the clutch basket in the same order and orientation as noted during removal.
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 (see page 4-8). They must be fitted in their noted positions.
1. Steel plate; 2. Inner fiction plate; 3. Anti-judder spring; 4. Anti-judder seat washer; 5. Clutch inner drum
11. Refit the clutch pull-rod.
12. Refit the clutch pressure plate together with the springs and bolts. Tighten the bolts to 10 Nm.
Note: The pull-rod should be free to move in and out and also it should be free to turn.
13. Clean and refit the clutch cover incorporating a new gasket. Tighten the clutch cover bolts to 9 Nm.
1. Clutch cover
14. Refit the clutch cable to the actuating arm at the clutch end (see page 4-5).
15. Set the clutch adjustment (see page 4-5).
16. Reconnect the battery positive (red) lead first.
17. Refit the rider's seat (see page 16-13).