Clutch/Kickstarter/Gearshift Linkage Service Information; Clutch/Kickstarter/Gearshift Linkage Torque Values; Clutch/Kickstarter/Gearshift Linkage Tools - Honda TRX450R Service Manual

CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE ('04 - '05)
SERVICE INFORMATION
GENERAL
• This section covers service of the clutch, kickstarter and gearshift linkage. These services can be performed with the
engine installed in the frame.
• Transmission oil viscosity and level and the use of oil additives have an effect on clutch disengagement. Oil additives of
any kind are specifically not recommended. When the clutch does not disengage or the vehicle creeps with the clutch
disengaged, inspect the transmission oil viscosity and level before servicing the clutch system.
SPECIFICATIONS
Unit: mm (in)
ITEM
Clutch
Kickstarter
Lever free play
Spring free length
Disc A thickness
Disc B thickness
Plate warpage
Pinion gear I.D.
Spindle I.D.
Idle gear I.D.
Idle gear bushing I.D.
O.D.
Countershaft O.D. at kickstarter idle gear
STANDARD
10-20(3/8-3/4)
45.7(1.80)
2.92-3.08(0.115-0.121)
3.22-3.38(0.127-0.133)
-
22.007 - 22.028 (0.8664 - 0.8672)
21.959 - 21.980 (0.8645 - 0.8654)
21.020-21.041 (0.8276-0.8284)
17.000 - 17.018 (0.6693 - 0.6700)
20.979 - 21.000 (0.8259 - 0.8268)
16.966 - 16.984 (0.6680 - 0.6687)
SERVICE LIMIT
-
44.7 (1.76)
2.85 (0.112)
3.15(0.124)
0.15(0.006)
22.05 (0.868)
21.95 (0.864)
21.07 (0.830)
17.04(0.671)
20.96 (0.825)
16.95(0.667)
TORQUE VALUES
Clutch spring bolt
Clutch center lock nut
Gearshift drum center pin bolt
Gearshift drum stopper arm bolt
Kickstarter pedal bolt
12N-m(1.2kgfm,9lbf-ft)
108 N-m (11.0 kgf-m, 80 Ibf-ft)
22 N-m (2.2 kgf-m, 16 Ibfft)
12 N-m (1.2 kgfm, 9 Ibf-ft)
38 N-m (3.9 kgf-m, 28 Ibf-ft)
Apply oil to the threads and seating surface.
Apply locking agent to the threads.
TOOLS
Clutch center holder
07724-0050002
or 07724-0050001 or equivalent
commercially available in U.S.A.
13-3