Partial Disassembly
This procedure can be performed without removing the clutch shell or hub. For replacement of the shell or hub, see 5.6 CLUTCH: CONVENTIONAL, Clutch Pack and Bearing.
1. Remove primary chaincase cover. See 5.3 PRIMARY CHAINCASE COVER, Removal.
2. See Figure 5-39. Remove three bolts (1) to release stopper plate (2) from clutch hub (6). Loosen each bolt gradually and in a star sequence around the hub.
NOTE
Do not lose the coil spring seats (5).
3. Remove stopper plate, three coil springs (4), coil spring seats and pressure plate (11) from clutch hub.
4. Remove the three spring seats from the clutch pressure plate.
5. Remove friction plates (12,14), steel plates (13) from clutch hub.
Cleaning And Inspection
Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a)
1. Wash all parts in cleaning solvent, except for friction plates and bearing, if removed. Dry parts with low-pressure, compressed air.
NOTE
Replace any damaged spring seats.
2. Check friction plates:
a. Use compressed air to remove all lubricant from the friction plates. Do not wipe off with a rag.
b. Measure the thickness of each plate.
c. If the thickness of any plate is less than 0.143 in (3.62 mm), replace with a complete new set.
d. Look for worn or damaged fiber surface material (both sides).
NOTE
Friction plates and steel plates are only sold as a kit.
3. Check the steel plates:
a. Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.
b. Check each plate for distortion. Lay the plate on a precision flat surface. Insert a feeler gauge between the plate and the flat surface in several places.
Replace any steel plate that is warped more than 0.006 in (0.15 mm).
4. Hold the clutch hub and rotate the clutch shell to check bearing for smooth operation. Replace the bearing if it runs rough, binds or has any end play. See 5.6 CLUTCH: CONVENTIONAL, Clutch Pack and Bearing.
5. Replace clutch shell if primary chain sprocket or starter ring gear are worn or damaged.
6. Replace clutch hub and shell if slots for clutch plates are worn or damaged.
7. Replace coil springs and stopper plate if either are cracked or bent.
Assembly
NOTE
Submerge and soak all friction plates in primary chaincase lubricant for at least five minutes.
1. Install the three spring seats in the clutch pressure plate.
NOTE
Verify that there are two narrow friction plates with a narrow steel plate between them on the clutch pressure plate during assembly.
2. See Figure 5-39. Install a narrow friction plate (14), then a narrow steel plate (13), then narrow friction plate on the pressure plate (11).
3. Install a narrow friction plate (14) and then a steel plate (13) on the clutch hub (6). Install seven remaining sets in the same manner, alternating between steel plates and friction plates.
4. Install clutch hub/plate assembly into the clutch shell, aligning the tabs as they enter.
NOTES
• The pressure plate is installed properly when the stopper plate bolts (1) will start into the clutch hub without distorting the stopper plate.
• Alternately tighten the three bolts 1-2 turns to prevent damage to the stopper plate.
• Verify the pressure plate splines are aligned with the splines on the hub.
5. Install pressure plate/plate assembly to the clutch hub.
Rotate pressure plate to align holes with threaded bosses on hub.
6. Install three coil springs (4) in pressure plate.
7. Align holes in stopper plate (2) with threaded bosses on clutch hub. Install stopper plate.
8. Install three bolts (1) (metric) to secure stopper plate and coil springs to clutch hub. Alternately tighten to 70-100 in-lbs (7.9-11.3 Nm).
NOTE
Always install a new gasket between primary cover and housing. Not replacing this gasket may cause primary chaincase leaks.
9. Install primary chaincase cover. Fill primary chaincase.
See 5.3 PRIMARY CHAINCASE COVER, Removal.
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