Partial Disassembly
This procedure can be performed on the motorcycle without removing the clutch shell or hub.
1. Remove primary chaincase cover. See 5.3 PRIMARY CHAINCASE COVER, Removal.
2. See Figure 5-30. Remove six bolts (1) (metric) to release diaphragm spring retainer (2) from clutch hub. Loosen each bolt gradually and in a star sequence around the hub.
3. Remove diaphragm spring retainer, diaphragm spring (3) and pressure plate (4) from clutch hub.
4. Remove friction plates (5, 7), steel plates (6), damper spring (8) and damper spring seat (9) from clutch hub (11).
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.
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 with a dial caliper or micrometer.
c. If the thickness of any plate is less than 0.143 in. (3.62 mm), discard all friction plates and replace with an entirely new set.
d. Look for worn or damaged fiber surface material (both sides).
NOTE
Replace all nine friction plates with an entirely new set if any individual plate shows evidence of wear or damage.
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.
5. Inspect the primary chain sprocket and the starter ring gear on the clutch shell. Replace the clutch shell if either are badly worn or damaged.
6. Check the slots that mate with the clutch plates on both the clutch shell and hub. Replace if slots are worn or damaged.
NOTE
Springs are identified by a dab of paint on one face. See the parts catalog to verify the correct spring is installed.
7. Check the diaphragm spring and diaphragm spring retainer for cracks or bent tabs. Replace part if either condition exists.
Assembly
NOTE
Submerge and soak all friction plates in primary chaincase lubricant for at least five minutes.
1. See Figure 5-31. Install the narrow friction plate on the clutch hub.
2. See Figure 5-30. Install damper spring seat (9) on clutch hub (11). It must sit inboard of narrow friction plate (7).
NOTE
See Figure 5-36. Notice damper spring (4) orientation with respect to damper spring seat (3).
3. See Figure 5-30. Install damper spring (8) on clutch hub with the concave side facing away from damper spring seat.
4. Install a steel plate (6) with round edge outward and then a friction plate (5) on the clutch hub. Install seven remaining sets in the same manner, alternating between steel plates and friction plates.
5. Install pressure plate (4) on clutch hub aligning holes in plate with threaded bosses on hub.
6. Seat diaphragm spring (3) in recess of pressure plate with the concave side inward.
7. Align holes in diaphragm spring retainer (2) with threaded bosses on clutch hub. Tabs on spring retainer contact flats on inboard side of bosses.
8. Install six bolts (1) (metric) to secure diaphragm spring retainer to clutch hub. Alternately tighten to 70-100 in-lbs (7.9-11.3 Nm).
NOTE
Always install a new gasket between primary chaincase cover and chaincase. Failure to replace this gasket may cause primary chaincase leaks.
9. Install primary chaincase cover. Fill primary chaincase with lubricant. See 5.3 PRIMARY CHAINCASE COVER, Installation.
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