Refer to “clutch removal” and “clutch installation” .
Clutch drive and driven plate
Note wipe off the engine oil from the drive and driven plates with a clean rag. |
Measure the thickness of drive plates with a vernier calipers. If the drive plate thickness is found to have reached the limit, replace it with a new one.
Special tool
(a): 09900–20102 (vernier calipers
(200 mm))
Clutch drive plate thickness service limit (no. 1 And no. 2 Drive plates): 2.92 Mm (0.115 In)
Measure the claw width of drive plates with a vernier calipers. Replace the drive plates found to have worn down to the limit.
Special tool
(a): 09900–20102 (vernier calipers
(200 mm))
Clutch drive plate claw width service limit (no. 1 And no. 2 Drive plates): 12.90 Mm (0.508 In)
Measure each driven plate for distortion with a thickness gauge and surface plate.
Replace driven plates which exceed the limit.
Special tool
(b): 09900–20803 (thickness gauge)
Clutch driven plate distortion service limit (no. 1, No. 2 And no.3 Driven plates): 0.10 Mm (0.004 In)
Clutch spring
Measure the free length of each coil spring with a vernier calipers, and compare the length with the specified limit.
Replace all the springs if any spring is not within the limit.
Special tool
(a): 09900–20102 (vernier calipers
(200 mm))
Clutch spring free length service limit: 55.3 Mm (2.18 In)
Clutch release bearing
Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.
Smooth engagement and disengagement of the clutch depends on the condition of this bearing.
Push rod (right)
Inspect the push rod for wear and damage.
If any defects are found, replace the push rod with a new one.
Clutch sleeve hub and primary driven gear assembly
Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates. If necessary, replace it with a new one.
Wave spring washer
Measure the free height “a” of each wave spring washer with a vernier calipers.
If each wave spring washer height “a” is not within the specified limit, replace it with a new one.
Special tool
: 09900–20102 (vernier calipers (200
mm))
Wave spring washer height “a” service limit: 4.30 Mm (0.169 In)
Clutch lifter drive cam and clutch lifter driven cam
Inspect the clutch lifter drive cam and clutch lifter driven cam for wear and damage. If any defects are found, replace the clutch lifter drive cam or clutch lifter driven cam.
Transmission components
2Nd drive gear
6Th drive gear
3Rd/4th drive gear
5Th drive gear
Countershaft/1st drive gear
Driveshaft
2Nd driven gear
6Th driven gear
3Rd driven gear
4Th driven gear
5Th driven gear
1St driven gear
Gearshift cam stopper
Gearshi ...
Show data when trouble (displaying data at
the time of DTC)
Use of sds
Ecm stores the engine and driving conditions (in the form of data as shown in
the figure) at the moment of the
detection of a malfunction in its memory. This data is called “show data when
trouble”.
Therefore, it is possible to know engine and driving conditions (e.G., Whether
...
Front brake pad replacement
Loosen the pad mounting pins (1).
Remove the brake caliper by removing the caliper
mounting bolts (2).
Remove the pad mounting pins (1), brake pads and
spring.
Caution
do not operate the brake lever while the pads
are removed.
Note
when ...