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d. Damper Reassembly
1) Install thin plate washer, thrust bearing and
thick plate washer in that order.
Install damper springs.
2)
Install collar.
3)
4) Use press and special tool t o install circlip.
CAUTION:
When installing circlip, the
damper pin must be positioned in the
center of the damper cam. Damage t o the
damper assembly could result from im-
proper positioning.
3. Clutch Housing
a.
Check dogs on clutch housing. Look for cracks
and signs of galling on edges.
moderate, deburr.
housing.
NOTE: Galling on the friction plate dogs of
the clutch housing will cause erratic clutch
operation.
b. Apply a thin film of oil t o transmission main
shaft and inside surface of clutch housing. Slip
clutch housing over main shaft.
4. Clutch Boss
b. The clutch boss contains a built-in damper be-
neath the first clutch plate (clutch plate 2). lt
is not normally necessary to remove thecirclip
and disassemble the built-in damper unless
is
there
serious clutch chattering.
b. Check splines on clutch boss for galling. I f
damage is slight t o moderate, deburr. I f it is
severe, replace clutch boss.
If
damage
If
severe, replace clutch
NOTE:
cause erratic clutch operation.
5.
Friction and Clutch Plates
Check clutch steel plates and friction plates
for heat damage. Measure friction plate thick-
ness at
for warpage with
place clutch plate or friction plates as
any is faulty or beyond wear limits.
Friction plate
thickness
I
Clutch plate
warp limit
6.
Clutch Push Rod
Check ends of clutch push rod for indenta-
tion. If severe, clutch adjustment may be dif-
ficult. Check for loosenessof the steel ends of
the push rod. I f ends are loose or indented,
replace push rod.
7.
Clutch Springs
Measure clutch spring free length. Replace
springs as a set i f any is less than minimum
free length.
Clutch spring minimum length:
is
M. Transmission
1. Inspect each shift fork for signs of galling on
gear contact surfaces. Check for bending. Make
sure each fork slides freely on i t s guide bar.
Roll the guide bars across a surface plate. I f
2.
any bar is bent, replace.
Check the shift cam grooves for signs of wear
3.
or damage. I f any profile has excessive wear
and/or damage, replace cam.
4. Check the cam followers on each shift fork for
wear. The follower should fit snugly into i t s
seat in the shift fork, but should not be overly
tight. Check the ends that ride in the grooves
in the shift cam. I f they are worn or damaged,
replace followers.
Galling on clutch plate splines will
3
or 4 points. Measure clutch plates
a
dial gauge and stand. Re-
Standard
3.0mm
(0.12 in.)
I
4.15mm (1.63 in.)
a set
if
Wear Limit
2.8mm
(0.11 in.)
I
0.05mm
in.)
(0.002
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