CLUTCH/STARTER CLUTCH/GEARSHIFT LINKAGE
9-3
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch, starter clutch and gearshift linkage. All service can be done with the engine
installed in the frame.
• Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the
motorcycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.
SPECIFICATIONS
Unit: mm (in)
TORQUE VALUES
ITEM STANDARD SERVICE LIMIT
Clutch lever freeplay 10 – 20 (3/8 – 13/16) –
Clutch Spring free length 48.2 (1.90) 47.2 (1.86)
Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.6 (0.10)
Plate warpage – 0.30 (0.012)
Clutch outer guide I.D. 24.993 – 25.003 (0.9840 – 0.9844) 25.013 (0.9848)
O.D. 34.996 – 35.004 (1.3778 – 1.3781) 34.986 (1.3774)
Primary driven gear I.D. 41.000 – 41.016 (1.6142 – 1.6148) 41.026 (1.6152)
Oil pump drive sprocket
guide
I.D. 25.000 – 25.021 (0.9843 – 0.9851) 25.031 (0.9855)
O.D. 34.950 – 34.975 (1.3760 – 1.3770) 34.940 (1.3756)
Oil pump drive sprocket I.D. 35.025 – 35.145 (1.3789 – 1.3837) 35.155 (1.3841)
Mainshaft O.D. at clutch outer guide 24.980 – 24.990 (0.9835 – 0.9839) 24.960 (0.9827)
Mainshaft O.D. at oil pump drive sprocket guide 24.980 – 24.990 (0.9835 – 0.9839) 24.960 (0.9827)
Starter idle gear Gear I.D. 10.013 – 10.035 (0.3942 – 0.3951) 10.05 (0.396)
Shaft O.D. 9.991 – 10.000 (0.3933 – 0.3937) 9.98 (0.393)
Starter driven gear boss O.D. 45.657 – 45.673 (1.7975 – 1.7981) 45.642 (1.7969)
Clutch center lock nut 128 N·m (13.1 kgf·m, 94 lbf·ft) Apply engine oil to the threads and seat-
ing surface.
Stake.
Clutch spring bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Oil pump driven sprocket bolt 15 N·m (1.5 kgf·m, 11 lbf·ft) Apply a locking agent to the threads.
Starter clutch outer mounting bolt 83 N·m (8.5 kgf·m, 61 lbf·ft) Apply engine oil to the threads and seat-
ing surface.
Shift drum center socket bolt 23 N·m (2.3 kgf·m, 17 lbf·ft) Apply a locking agent to the threads.
Shift drum stopper arm pivot bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply a locking agent to the threads.
Gearshift spindle return spring pin 22 N·m (2.2 kgf·m, 16 lbf·ft)
Gearshift arm pinch bolt 20 N·m (2.0 kgf·m, 15 lbf·ft)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.
email: info@motomatrix.co.uk
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