Inspection

Anin-situcheckcanbemadeasfollows:

1. Checkforsignificantbluediscolourationofthechainplatesindicatingexcessiveheatbuild-up.

2. Examineallpinsforsignsofrotation.

3. Checkforcrackingordeepscratchingofthechainplates.

4. Checkforseverewearoftheinner platesasindicatedinthediagrambelow.

""''

Foramorethoroughcheck,proceedasfollows:

1. Removethechainfromtheengine.

2. Suspendthechainfromapinorhookwitha13kgweightattachedatthelowerend.

3. Measureacross23linksasshowninthediagram.Ifthechainiswithinlimits,themeasurementshouldbenolongerthan147.63mm.Measurementsbeyond147.63mmindicatethatthechainmustbereplaced.

3.18 ServiceManual-RocketIll

6. Checkforseverewearoftheplatesintheareashownbelow.

4. Checkforseverewearoftheinnersurfaceoftheouterplatesattheside-contactpointswiththesprocketteeth.

^-Ifanyofthesesymptomsare evident,thecam

5. Checkforsignsofstiffnessorkinking.

chainmustbereplaced.

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3.19

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20. ServiceManual-RocketIll

4Clutch

TableofContents

ExplodedView-ClutchControls 4.2

ExplodedView-Clutch. 4.3

ExplodedView-ClutchCover 4.4

ClutchCable 4.5

Removal 4.5

Examination 4.6

Installation 4.6

ClutchCover 4.7

Removal 4.7

Installation 4.7

Clutch 4.7

Removal 4.7

FrictionPlateInspection 4.9

Thickness 4.9

Assembly 4.9

• ServiceManual-RocketIll ^4.1

ExplodedView-ClutchControls

_r3Nm

_'3Nm

3Nm

^4.2 Service Manual-RocketIll

ExplodedView-Clutch

·_I

@

10Nm

ServiceManual-RocketIll ^4.3

ExplodedView- ClutchCover

4.4 ServiceManual-RocketIll

ClutchCable

Removal

1. Removetherider'sseatasdescribedonpage

17.9.

2. Disconnectthebattery,negative{black)leadfirst.

3. Slackenthecablelocknut andreleasetheadjusterattheengineenclto givemaximumplayinthecable.

1. ClutchCable

2. Adjuster

4.Releasetheclutchcablefromtheactuatingarmbypushingtheinnercable nipplethroughthearmandslidingthecable out.Detachthecablefromthebracket.

1. ActuatingArm

2. InnerCable

5. Aligntheslotsintheleveradjusterandlocknut.

1. Locknut

2. Leveradjuster

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4.5

6.Pullintheclutchleverandturntheinnercable,anti-clockwisethroughtheslotsintheadjusterandlocknut,untilthecablecanbedetachedfromthelever.

1. Nut/locknutSlots

2. CableReleasePoint

7. Removethecablefromthemotorcycle notingthecablerouting,particularlywhereitpassesthroughsteeringarea.

Note:

• Toensurethesameroutecanbefollowedoninstallation,tiealengthofstringtooneendwhilepullingthecablethroughfromtheother.Wheninstallingthenewcable,tiethestringtooneendofthecableanduseittoguidethenewcableintoposition.

Examination

1. Checktheinnercableforfreemovementthroughtheoutercable.

2. Examinetheinnercableforfrayedstrands.

3. Examinethetwoinnercablenipplesforsignsofloosenessanddamage.Replacethecableifnecessary.

Installation

1. Positionthecabletothemotorcyclefollowingthesameroutingasnotedduringremoval.

2. Attachtheinnercabletotheclutchleverandactuatingarmusingareversalofthe removalprocess.

3. Refittheoutercabletotheadjuster bracketattheengineend.

Note:

• Ensure thatthetwoadjusternutsarepositioned,oneeithersideofthe bracket.

Settheleveradjustertoapointwhereanequaladjustmentispossibleinbothdirections.

Settheadjusterat theclutchendtogiveapreliminarysettingof2-3mmoffreeplayasmeasuredatthelever.

Operatetheclutchleverseveraltimes andrechecktheamountoffree-playpresent.

Setthefinaladjustmentofthecabletogive2-3mmof free-playattheleverbyturningtheadjusternutandlocknutattheleverend.Securethesettingwiththeknurledlocknut.

1. ClutchLever

2. CorrectSetting,2-3 mm

8. Reconnectthebatterypositive(red)leadfirst.

9. Refittherider'sseat.