Clutch lever too hard to pull in

• Damaged, kinked or dirty clutch cable

• Improperly routed clutch cable

• Damaged clutch lifter mechanism

• Faulty clutch lifter plate bearing

 

Clutch will not disengage or motorcycle creeps with clutch disengaged

• Excessive clutch lever freeplay

• Clutch plate warped

• Engine oil level too high, improper oil viscosity or additive used

• Loose clutch center lock nut

 

Clutch slips

• Clutch lifter sticking

• Worn clutch discs

• Weak clutch springs

• No clutch lever freeplay

• Engine oil level too low or oil additive used

 

Hard to shift

• Misadjusted clutch cable

• Damaged or bent shift fork

• Bent shift fork shaft

• Incorrect engine oil viscosity

• Bent or damaged gearshift spindle

• Damaged shift drum stopper plate

• Damaged shift drum guide grooves (page 14-11)

 

Transmission jumps out of gear

• Worn shift drum stopper arm

• Worn or broken gearshift spindle return spring

• Bent shift fork shaft

• Worn or damaged shift drum stopper plate

• Damaged shift drum guide grooves (page 14-11)

• Worn gear dogs or dog holes (page 14-11)

 

Gearshift pedal will not return

• Weak or broken gearshift spindle return spring

• Bent gearshift spindle

 

 

12-2

CLUTCH/GEARSHIFT LINKAGE

COMPONENT LOCATION

 

 

12 N·m (1.2 kgf·m, 9 lbf·ft)

 

108 N·m (11.0 kgf·m, 80 lbf·ft)

 

10 N·m (1.0 kgf·m, 7 lbf·ft)

 

 

108 N·m (11.0 kgf·m, 80 lbf·ft)

 

 

10 N·m (1.0 kgf·m, 7 lbf·ft)

 

 

12-3

CLUTCH/GEARSHIFT LINKAGE

RIGHT CRANKCASE COVER

 

REMOVAL

 

Drain the engine oil (page 3-9).
[4]		[3]		[2]
Drain the coolant (page 9-5).

Remove the following:

 

– Water pipe (page 9-13)

– Frame guard (page 2-6)

– Brake pedal (page 18-12)

 

Remove the bolts [1] and clutch cable guide [2], then disconnect the clutch cable [3] from the clutch lifter arm [4].

 

[1]

 

Be careful not to let the return spring fall into the crankcase.

 

Loosen the water hose band screw [1] and disconnect the water hose [2].

 

Remove the bolt [3] and rear brake light switch holder [4].

 

 

Loosen the right crankcase cover bolts [1] in a crisscross pattern in 2 or 3 steps and remove the bolts.

 

Remove the right crankcase cover [2] while turning the clutch lifter arm [3] counterclockwise to disengage the lifter arm spindle from the lifter piece.

 

 

		[4]
[2]

 

 

		[3]
[1]

[3]

 

	[2]		[1]
Remove the dowel pin A [1], dowel pin B [2] and gasket
[1]			[2]
[3].

 

 

[3]

 

 

12-4

CLUTCH/GEARSHIFT LINKAGE

Remove the collars [1] and O-rings [2].

 

[1]/[2]

 

DISASSEMBLY

 

Remove the return spring [1] from the right crankcase cover.

 

 

[1]

 

Remove the clutch lifter arm [1] from the right crankcase cover.

 

 

[1]

 

INSPECTION

 

Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary.

 

– Oil seal

– Clutch lifter arm needle bearing

– Clutch lifter arm

– Return spring

– Crankshaft bearing

 

12-5

CLUTCH/GEARSHIFT LINKAGE

BEARING REPLACEMENT

 

CRANKSHAFT BEARING
Remove the crankshaft bearing [1] using the special
[2]		[3]
tools.
TOOLS:
[2] Remover weight	07741-0010201
[3] Bearing remover set, 12 mm	07936-1660101

 

 

[1]

 

Drive in a new crankshaft bearing [1] into the right crankcase cover with the marked side facing up until it is fully seated using the special tools.

 

TOOLS:
[2] Driver	07749-0010000
[3] Attachment, 28 x 30 mm	07946-1870100
[4] Pilot, 12 mm	07746-0040200

 

After installation, apply engine oil to the bearing.

 

CLUTCH LIFTER ARM NEEDLE BEARING

 

Remove the oil seal [1] from the right crankcase cover.

 

Remove the clutch lifter arm needle bearings [2] using the special tools.

 

TOOLS:
[3] Bearing remover set, 12 mm	07936-1660101
[4] Remover weight	07741-0010201

 

[2]

 

[3]/[4]

 

 

[1]

 

 

[2]

[1]

[4]

 

 

[2] [3]

 

 

12-6

CLUTCH/GEARSHIFT LINKAGE

 

Install the bearing remover head [1] to the pilot collar [2] as shown.

 

TOOLS:
[1] Bearing remover head, 10 mm	07746-0050200
[2] Pilot collar, 16 mm	07PAF-0010620

 

[1]

 

[2]

 

Drive in a new clutch lifter arm needle bearings [1] until the specified depth, using the special tools as shown.

 

TOOLS:
[2] Bearing remover head, 10 mm	07746-0050200
[3] Pilot collar, 16 mm	07PAF-0010620

 

After installation, apply engine oil to the bearing.

 

[1]

6.5 – 7.5 mm

 

(0.26 – 0.30 in)

 

Install a new oil seal [1] to the right crankcase cover as shown.

 

ASSEMBLY

 

Apply grease to the clutch lifter arm oil seal lips [1]. Apply molybdenum oil solution to the clutch lifter arm [2] sliding surface.

 

Install the clutch lifter arm to the right crankcase cover.

 

			49.0 –
			50.0 mm
			(1.93 –
			1.97 in)
[3]		[2]

 

 

0.5 – 1.0 mm

 

(0.02 – 0.04 in)

 

 

[1]

 

 

[1]			[2]

 

 

12-7

CLUTCH/GEARSHIFT LINKAGE

 

Be careful not to damage the mating surfaces.

 

Be careful not to let the return spring fall into the crankcase.

 

Install the return spring [1] to the right crankcase cover by aligning the spring short end with the hole of the clutch lifter arm and long end with the groove of the right crankcase cover.

 

INSTALLATION

 

Clean any gasket material from the mating surfaces of the right crankcase and cover.

 

Apply engine oil to new O-rings [1]. Install the collars [2] and O-rings.

 

Install the dowel pin A [1], dowel pin B [2] and a new gasket [3].

 

Install the right crankcase cover [1] while turning the clutch lifter arm [2] clockwise to engage the lifter arm spindle groove with the lifter piece flange.

 

Install and tighten the bolts [3] in a crisscross pattern in 2 or 3 steps.

Align

 

Align

[1]

 

[1] /[2]

[1]

[2]

 

[3]

[2]

 

 

[1]

[3]

 

12-8

CLUTCH/GEARSHIFT LINKAGE

 

Connect the water hose [1] and tighten the water hose band screw [2] (page 9-7).

 

Install the rear brake light switch holder [3] and tighten the bolt [4].

 

 

Connect the clutch cable [1] to the clutch lifter arm [2].

 

Install the clutch cable guide [3] and bolts [4].

 

Tighten the bolts securely.

 

Install the following:

 

– Brake pedal (page 18-12)

– Frame guard (page 2-6)

– Water pipe (page 9-13)

 

Adjust the clutch lever freeplay (page 3-18).

 

Fill the engine with the recommended engine oil (page 3-9).

 

Fill the recommended coolant and bleed the air (page 9-5).

 

CLUTCH

 

REMOVAL

 

Remove the right crankcase cover (page 12-4).

 

Loosen the clutch lifter plate bolts [1] in a crisscross pattern in 2 or 3 steps.

 

Remove the clutch lifter plate bolts and clutch springs [2].

 

Remove the clutch lifter plate [3]. Remove the clutch discs [4] and plates [5].

 

Remove the clutch lifter piece [1], judder spring [2] and spring seat [3].

 

		[3]
[1]

 

 

						[4]
				[2]
[2]						[3]
	[1]

 

[4]

 

 

[1]/[2]

[4]/[5]

 

 

[3]

[2]/[3]

 

 

[1]

 

 

12-9

CLUTCH/GEARSHIFT LINKAGE

 

Unstake the clutch center lock nut [1].

 

 

Hold the clutch center [1] with the special tool and loosen the clutch center lock nut [2].

 

TOOL:
[3] Clutch center holder	07724-0050002

 

Remove the clutch center lock nut and washer [4].

 

 

Remove the washer [1] and clutch outer [2].

 

 

Remove the needle bearing [1], clutch outer guide [2] and washer [3] from the mainshaft.

 

 

Unstake

 

[1]

[3]

[2]/[4]

 

 

[1]

[2]

[1]

 

[1]

[3]

 

 

[2]

 

 

12-10

CLUTCH/GEARSHIFT LINKAGE

 

INSPECTION

 

Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary.

 

– Clutch lifter bearing

– Clutch springs

– Clutch center

– Clutch discs/plates

– Clutch outer

– Clutch outer guide/needle bearing

– Mainshaft

 

Measure each part according to CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS (page 1-7).

 

Replace any part if it is out of service limit.

 

• Replace the clutch springs as a set.

• Replace the clutch discs and plates as a set.