Caution

Clutch release shaft removal damages the oil seal in the clutch cover necessitating the oil seal replace­ment.

• Slide the dust cover at the clutch cable lower end out of place.

• Loosen the nuts, and slide the lower end of the clutch cable to give the cable plenty of play.

• Loosen the knurled locknut [B] at the clutch lever, and screw in the adjuster [C].

• Remove the left handlebar cover.

• Line up the slots [A] in the clutch lever, knurled locknut, and adjuster, and then free the cable from the lever.

6-10 CLUTCH

Right Engine Cover

• 

  Free the clutch inner cable tip from the clutch release lever [A].

• Turn the release lever toward the rear [B] as shown in the figure. Pull the lever and shaft assembly out of the clutch cover.

Clutch Release Installation

Caution

Always install a new oil seal when the clutch release shaft is removed.

CAUTION

When inserting the release shaft, be careful not to remove the spring of the oil seal.

• Apply high temperature grease to the oil seal lips in the clutch cover.

• Apply engine oil to the bearings in the hole of the clutch cover.

• Apply engine oil to the release shaft.

• Turning the release lever toward the rear, insert the re­lease shaft straight into the hole of the clutch cover.

• 

  Install the clutch inner cable tip in the release lever.

• Turn the release lever clockwise until it becomes hard to turn.

○The release lever should have proper clearance and an­gle as shown.

1 ∼ 3 mm

80° ∼ 90°

CLUTCH 6-11

Clutch

Clutch Removal

• Drain the engine oil (see Engine Oil Change in the Peri­odic Maintenance chapter).

• Remove the clutch cover (see Clutch Cover Removal).

• Remove the clutch spring bolts [A], washers [B] and springs.

• Remove the clutch spring plate [C] with the thrust ball bearing [D] and pusher [E]. Remove the friction plates and steel plates.

• When loosening the clutch hub self-locking nut [A], use the clutch holder [B] to keep the clutch hub from turning as shown.

Special Tool - Clutch Holder: 57001-1243

Remove the clutch hub self-locking nut and washer.

• Pull out the clutch hub [A] and thrust washer [B].

NOTE

○The clutch housing can not be removed without major disassembly work (see Crankshaft/Transmission chap­ter).

Clutch Installation

• Install the thrust washer and clutch hub.

• Install the washer.

• Discard the used clutch hub self-locking nut, and install a new self-locking nut with the projected side facing out­ward.

• Install the clutch holder to keep the clutch hub from turning and tighten the clutch hub self-locking nut.

Special Tool - Clutch Holder: 57001-1243

Torque - Clutch Hub Nut: 132 N-m (13.5 kgf-m, 98 ft-lb)

• Install the friction plates and steel plates, starting with a friction plate and alternating them.

6-12 CLUTCH

Clutch

○The grooves [A] on the friction plate surfaces are cut tan-gentially and radially, install the friction plates so that the grooves run toward the center in the direction of the clutch housing rotation (counterclockwise viewed from the en­gine right side).