clutch/gearshift linkage

8/14/2019 Clutch/Gearshift Linkage

1/19

LINKAGE

12 N-m (1 kgf-m, 9 Ibf-ft)

12 N-m (1.2'kgf-m, 9 Ibf-ft)


2/19

9. CLUTCH/GEARSHIFT LIN E

ITEM

Clutch lever free play

SERVICE INFORMATION 9-1 CLUTCH

STANDARD SERVICE LIMIT

10-

20 (318- 13/16) -

9-4 ~

Clutch spring free length 48.8 (1.92)

TROUBLESHOOTING 9-2 GEARSHIFT LINKAGE 9-12

RIGHT CRANKCASE COVERREMOVAL 9-3 INSTALLATION 9-17

RIGHT CRANKCASE COVER

47.4 (1.87)

SERVICE INFORMATI0N

Clutch disc thickness

Clutch plate warpage

GENERAL

2.92 - 3.08 (0.114 - 0.121) , 2.6 (0.10)- 1 0.30 (0.012)

This section covers service of the clutch, gearshift linkage, shift drum and shift forks. All service can be done wit h theengine installed in the frame.Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the m otor -

cycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.

Claw thickness

Fork shaft O.D.

5.93 - 6.00 (0.233 - 0.236)

11.957- 11,968 (0.4707 - 0.4712)

5.9 (0.23)11.95 (0.470)

Clutch outer guide I.D.I O.D. 1 25.000 - 25.021 (0.9843 - 0.9851)~ 34.975 - 34.991 (1.3770 - 1.3776) 1 25.03 (0.985)' 34.97 (1.377)1 24.96 (0.983) IMainshaft O.D. at clutch outer qu ide ~ 24.980 - 24.993 (0.9835 - 0.9840)

Shift fork, fork 1 Fork 1 I.D. ~ 1 12.000 - 12.018 (0.4724 - 0.4731) 1 12.03 (0.474) 1

ORQUE VALUES

lutch center lock nut

lutch spring bolt

hift drum center socket bolthift drum stopper arm piv ot bolt

earshift return spring p in

earshift dru m bea r ingkh i f t fork shafttaining bolt

earshift pedal link pinch boltil pum p driven sprocket bolt

127 N * m (13.0 kg f -m , 94 I b f - f t )12 N.m (1.2 kgf-m, 9 Ibf- f t )23 N * m (2.3 kgf-m, 17 Ib f - f t )12 N * m (1.2 kgf-m, 9 Ibf- f t )23 N - m (2.3 kgf-m, 17 Ib f - f t )

Apply oi l to the threads.Stake the nut.

Apply a locking agent to the threads.

12 N * m (1.2 kgf-m, 9 I b f W10 N- m (1.0 kgf-m, 7 I b f W15 N - m (1.5 kgf-m, 11 Ib f - f t )




3/19

LINKAGE

OOLS

lutch center holder 07724-0050002 or equivalent commercia lly available in U.S.A.

river 07749-0010000

tachment, 42 x 47 mm 07746-0010300

lot, 35 mm 07746-0040800

TROUBLESHOOTING

lutch lever too hard to pull inDamaged clutch lifter mechanism

Faulty clutch lifte r bearingClutch lifter piece installed improperly

utch slips when acceleratingWorn clutch disc

Weak clutch springsTransmission oil mixed wit h molybdenum or graphite addi-

tive

lutch will not disengage or motorcycle creeps wi th clutchsengagedClutch plate warped

Loose clutch lock nu t

Oil level too highImproper oil viscosity

Damaged clutch lifter mechanism

Clutch lifter piece installed improperly

ard to shiftImproper clutch operation

Improper oil viscosity

Bent shift fork

Bent shift fork shaft

Bent fork clawDamaged shift drum cam grooveLoose stopper plate bo lt

Damaged stopper plate and p in

Damaged gearshift spindle

Transmission jumps out of gearWorn shift dr um stopper arm

Weak or broken shift arm return spring

Loose stopper plate bolt

Bent shift fork shaftDamaged shift dr um cam groove

Damaged or bent shift forksWorn gear engagement dogs or slots

Gearshift pedal will not returnWeak or broken gearshift spindle return spring

Bent gearshift spindle

-2


4/19

CLUTCH/GEARSHIFT LINKAGERIGHT CRANKCASE COVER REMOVAL

Drain the engine oil (page 3-15).

Remove the l ower cowl (page 2-7).Open and support the front end o f the fuel tank (page

3-4).Disconnect the ignition pulse generator 2P (Red ) con-nector.

Remove the bolts and clutch cable bracket, then dis-

connect the clutch cable end from the clutch lifter

lever.

The iifterarmspindie is

wit Ihepiece lifter arm spindle from the lifter piece.insideth eright

crankcase cover

Remove the right crankcase cover SH bolts.

Remove the right crankcase cover while turning the

clutch lifter arm counterclockwise to disengage the

Remove the tw o do wel pins.

Clean any sealant off fr om th e rig ht crankcase cover

mat ing surfaces.

2P (RED) CONNECTOR


5/19

LINKAGE

Instail the hooksof the return

spring to the rightcrankcase coverand clutch lifter

lever.

CLUTCH

CLUTCH LIFTER LEVER

Remove the clutch lifter lever, return spring and wash -er from the right crankcase cover.

Check the lifter lever spindle for wear or damage.

Check the return spring for fatigue or damage.

WASHER LIFTER LEVER

Check the lifter lever o il seal and needle bearings for

wear or damage.Install the clutch lifter lever with the washer and

spring in the reverse order of removal.

REMOVAL

Remove the right crankcase cover (page 9-3).Remove the clutch spring bolts, springs and pressure

plate.

Remove the clutch lifter piece fr om the lifter bearing.

Remove the following:-

Nine clutch discs

- Eight clutch plates

- Judder spring- Judder spring seat

O l i SEAL


6/19

CLUTCH/GEARSHIFT LINKAGEUnstake the clutch center lock nut.

Hold the clutch center with the clutch center holder,

then remove the lock nut.

TOOL:Clutch center holder 07724-0050002

(Equivalent commer-

cially available inU.S.A.)

Discard the lock nut.

Remove the lock washer, thrust washer and clutch

center.

Remove the washer.

9-5


7/19

LINKAGE

Align the primary drive gear and sub-gear teeth witha screwdriver as shown.

Pull out the clutch outer.

Remove the oil p um p driven sprocket bolt/washer.Remove the oil pum p drive/driven sprocket and driv echain as an assembly.

Remove the clutch outer guide.

INSPECTlONClutch lifter bearing

Turn the inner race of the lifter bearing with yourfinger.

The bearing should turn smoothly and freely without

excessive play.

If necessary replace the bearing.

Clutch spring

Measure the clutch spring free length.

SERVICE LIMIT: 47.4 mm (1.87 in)

I PRIMARY DRIVE GEARISUB-GEAR

CLUTCH OUTER

LIFTER-BEARING

9-6


8/19

CLUTCH/GEARSHIFT LINKAGEClutch center

Check the grooves of the clutch center for damage o r

wear caused by the clutch plates.

Replace if necessary.

Clutch lifter piece

Check the clutch lifter piece for damage or abnormal

wear.

Clutch discReplace the clutch discs i f they show signs of scoring

or discoloration.

Measure the disc thickness of each disc.


Clutch plat eCheck each disc plate for warpage on a surface plateusing a feeler gauge.

SERVICE LIMIT: 0.30mm (0.012 in)

9-7


9/19

LINKAGE

Judder spring/spring seatCheck the judder spring and spring seat for deforma-

tion, warpage or damage; replace as necessary.- A damaged or warped spring seat will cause thejudder spring to be pressed unevenly.A damaged judder spring also causes the weak con-

tact between the discs and plates or unevendisc/plate contact.

Clutch outer/clutch outer guideCheck the slots of the clutch outer for damage or wear

caused by the clutch discs.

Replace i f necessary.

JUDDER SPRING/

SPRING SEAT

Measure the O.D. and I.D. of the cl utch outer guide.

SERVICE LIMITS:O.D.: 34.97 rnm (1.377 in)I.D.: 25.03 rnm (0.985 in)

Mainshaft

Measure the mainshaft O.D.at clutch outer guide slid-ing surface.

SERVICE LIMIT: 24.96 rnrn (0.983 in)

9-8


10/19

CLUTCH/GEARSHIFT LINKAGECLUTCH OUTER NEEDLE BEARINGREPLACEMENT

Press the needle bearing ou t of the clutch oute r using

the special tools.

TOOLS:Driver 07749-0010000

Attachment, 42 x 47 mm 07746-

0010300Pilot, 35 mm 07746-0040800

Press rhe needlebearing Into theouter withthemarkeds/de

Press a new needle bearing into the clutch outer SO

that the casing of the needle bearing is flush wi th t he

clutch outer surface as shown.

facing TOOLS:Driver 07749-0010000

Attachment, 42 x 47 mm 07746-

0010300Pilot, 35 mm 07746-0040800

iNSTALLATION

CLUTCt

CLUTCH DISCS

CLUTCH DISC (GREEN)

% LARGE I.D. CLUTCH DISC

SPRING SEAT

JUDDER SPRING

LOCK NUT

THRUSTWASHER

/ LIFTER PLATE12 N * m (1.2 kg f -m , 9 IbfW

9-9


11/19

LINKAGE

Align the pr imary drive gear and sub-gear teeth witha screwdriver as shown.

Install the clutch outer.

install theoi lpump driven

procket withits

OUT"mark fac-ingou t

PRIMARY DRIVE GEAR/SUB-GEAR

Install the clutch outer guide, and then install the oilpump dr ive idr iven sprocket and drive chain as anassem blv.

sure the clutch

er sits securely

to the position-g tabsof theoii

pump driveprocket. Rotate

e oil pump drive

chainwhileinstaiiing theciutch outer to

properly seat it.

Apply a locking agent to the threads of the oil pump

driven sprocket bolt.

Tighten the driven sprocket bolt to the specified

torque.

TORQUE: 15 N-m (1.5 k g f m , 11 Ibf-ft)

I C L U T ~ HOUTER IInstall the washer onto the clutch outer.

-10


12/19

CLUTCH/GEARSHIFT LINKAGEInstall the c lutch center.

Install the thrust washer.

Install the lock washer with its "OUT" mark facingout.

Apply oil to the new lock nut threads, then install it.

Hold the clutch center with the clutch center holder,

then tighten the lock n ut to the specified torque.

TOOL:Clutch center holder 07724-0050002

(Equivalent commer-

cially available inU.S.A.)TORQUE: 127 N-m (13.0 k g f- m . 9 4 I b f W

Becarefui not toshaft threads.

Stake the lock nut into the mainshaft groove with adamage the main- punch.

Install the judder spr ing seat'and judder spring. GREEN JUDDER SPRING

COLOREDCoat the clutch discs a nd plates wit h clean engine oil.Install the large I.D. clutch disc.

Stack the cl utch plates an d discs alternately.

CLUTCHmPLATES -7ify- -


13/19

LINKAGE

Install the green outer clutch disc in the shallow slot

on the clutch outer.

Install the lifter bearing into the pressure plate.

Install the clutch lifter piece into the lifter bearing.

Install the pressure plate.Install the clutch springs and spring bolts.

Tighten the bolts in a crisscross pattern in tw o t o three

steps, then tighten the bol ts to the specified torque.

TORQUE: 12N*m (1.2kgf-m,9 Ibfmft)Install the right crankcase cover (page 9-17).

GEARSHIFT LINKAGE REMOVAL

Remove the following :

- Right crankcase cover (page 9-3)- Clutch assembly (page 9-41Remove the bolt and gearshift pedal link.


14/19

CLUTCH/GEARSHIFT LINKAGE

Shiftdrum/shi f tforkservice can

be done withtheengineinstailed in

?,oeframe.

Pull the gearshift spindle assembly and thrust washer

out of the crankcase.

Remove the fol lowing:- Stopper arm socket bolt- Stopperarm

- Return spring- Washer-

Dowel pins-

Socket bol t

- Gearshift cam

GEARSHIFT LINKAGE INSPECTIONCheck the gearshift spindle for wear, damage or

bends.

Check the return spring for fatigue or damage.

SHIFT DRUM/SHB&TFORK REMOVALRemove the foll owing:- Gearshift linkage (page 9-12)

- Oil pan (page 4-3)

Remove the bolts and shift dr um bearing set plates.

3


15/19

LINKAGE

Remove the shift fork shaft and shift forks.

Remove the shift d rum bearing and shift d r u m .

SHIFT DRUM/SHIFT FORK INSPECTIONCheck the sh ift fork and fork shaft for wear or damage.

Measure the I.D. of the shift fork.


Measure the shift fork claw thickness.


Measure the O.D. of the shift fork shaft.


I SHIFT FORK SHAFT

I ' S H I F ~DRUM

Inspect the shift dr um grooves for wear or damage.

-14


16/19

CLUTCH/GEARSHIFT LINKAGETurn the outer race of the shift drum bearing with

your finger.

The bearing should turn smoothly and freely wit hout

excessive play.

If necessary replace the bearing.

SHIFT DRUM/SHIFT FORK INSTALLATIOMThe shift forks have location marks."R" for right"C" for center

"L" for left

IDENTIFICATION MARKS

Install the shift d rum ish i f t drum bearing into thecrankcase.

Apply molybdenum disulfide oil to the shifter forkgroove o f the shift gears.

Install the shift forks on the transmission with their

identification marks facing to the right.

Install the shift fork shaft.

RIGHT SHIFT ~ O R K CENTER ~ H I F TFORK

I SHIFT FORK SHAFT I

9-15


17/19

LINKAGE

Apply a locking agent to the threads of the set plate

bolts.

Install and set plates and bolts, tighten the bo lts to thespecified torque.

TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)Install the gearshift linkage (see foll owing steps).

GEARSHIFT LINKAGE INSTALLATION

Install the following :

- Washer

- Return spring

- Stopper arm

-

Socket bolt

Tighten the stopper a rm socket bo lt to the specified

torque.

TORQUE: 12 N-m (1.2 kgf-m, 9 Ibfqft)

Install the dowe l p in onto the shift drum .Install the gearshift cam while holding the stopper

arm using a screwdriver as shown.

the dowe ipin on the shift

rumcenterwiththe widegrooveon rhegearshift

cam

A p p l y a Ithreads. ck ing gent 3 the gearshift cam socket boltInstall and tighten the socket bolt to the specified

torque.

TORQUE: 23 N-m (2.3 kgf-m, 17 Ibf-ft)

-16


18/19

CLUTCH/GEARSHIFT LINKAGEInstall the thrust washer and gearshift spindle assem-bly i nto the crankcase while aligning the spring endswith the crankcase stopper pin.

Install the gearshift pedal link aligning its slit wi th the

punch mark on the gearshift spindle.Install and tighten the pinch bolt to the specifiedtorque.

TORQUE: 0 N m (1.0 k g f m , 7 Ibf-ft)Install the clutch assembly (page 9-9).

IGHT CRANKCASE COVER INSTALLATION 1 -Apply sealant

tothe mating surfaces of the crankcaseas shown.

Apply sealant to the mating surface of the rightcrankcase cover.

9-17


19/19

LINKAGE

Install the tw o dowel pins.

Install the right crankcase cover while turning the

lifter arm clockwise to engage the lifter arm groove

wi th th e lifter piece flange.

Install the right crankcase cover bolts.

Tighten the bolts crisscross pattern in two to three

steps securely.

Connect the clutch c i . . - . ~end to th e clutch li fter lever,then install the clutch cable bracket wi th th e tw o bolts.

Tighten the bolts securely.

clutch/gearshift linkage

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