Honda CRF250R 2005 Owner's Manual page 55

Clutch Disc Inspection
Replace the clutch discs (1) if they show signs of
scoring or discoloration.
Measure the thickness of each clutch disc.
Service Limit: 0.112 in (2.85 mm)
Replace the clutch discs and clutch plates as an
assembly.
(1) clutch disc
Clutch Spring Inspection
(1) clutch spring
Measure the free length of each spring.
Service Limit: 1.46 in (37.2 mm)
If one or more springs are beyond the service
limit, replace the springs as a set.
Clutch Disc/Plate Installation
1. Coat the clutch plates (1) with transmission
oil.
2. Install the eight clutch discs (2) and seven
clutch plates alternately, starting with a clutch
disc.
(1)
(2) (1)
(1) clutch plates
3. Apply grease to the clutch lifter rod (3).
4. Insert the clutch lifter rod into the mainshaft.
5. Install the clutch lifter (4) onto the rod.
(1)
(3) clutch lifter rod
6. Install the clutch pressure plate (5).
7. Install the five clutch springs and bolts (6).
8. Tighten the bolts in a crisscross pattern in 2 or
(5) clutch pressure plate
9. Install a new O-ring (7) in the groove of the
10. Install the cover by tightening the five cover
(2) clutch discs
(3)
(4)
(7) O-ring
(4) clutch lifter
Clutch System
3 steps, to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
(6)
(6) clutch spring bolts
clutch cover (8).
bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)
(8)
(7)
(8) clutch cover
Servicing Your Honda
(5)
(cont'd)
51