Honda XL350R 1984 Shop Manual page 103

8.
CLUTCH/OIL PUMP/
KICK STARTER
SERVICE INFORMATION
TROUBLESHOOTING
RIGHT CRANKCASE COVER REMOVAL
CLUTCH
OIL PUMP
DRIVE GEAR
KICK STARTER
GEARSHIFT DRUM STOPPER
RIGHT CRANKCASE COVER INSTALLATION
SERVICE INFORMATION
GENERAL
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• Th is sectio n covers removal and installation of the clutch, oil pump, and kick starter, starting with the right crankcase cover.
All these operations can be accomplished with the engine installed .
• When the existing clutch discs are replaced, coat new discs with engine oil prior to assembly.
• Clean the oil strainer whenever the right crankcase cover is removed.
SPECIFICATIONS
IT EM
STANDARD SERVICE LIMIT
Clu tch Lever free play (at lever end) 10-20
mm
(3/8 3/4
in)
Spring free length 35.4
mm
(1.39
in )
33 .7
mm
(1.33
in)
Spring preload/length 23.4-28.6 kg123
mm
(5 1. 59-63.05 Ib/D.9
in)
Disc thickness 2.92-3.08
mm
(0.11 5-0.121
in)
2.69
mm
(0.106
in)
Plate warpage 0 .3 mm (0.01 in)
Clutch outer I .D. 28.000- 28.021 mm (1.1024-1.103 2 in) 28.04 mm (1.104 in)
Clutch outer guide 0.0. 27.959-27.998 mm (1.1007 - 1.1023 in) 27.05 mm (1 .065 in)
1.0. 22.010- 22.035 mm (0 .8665-0.8675 in) 22.05 mm (0.868 in)
Mainshaft 0 .0 . 21.959- 21.980 mm (0.8645-0 .8654 in) 21.91 mm (0.863 in)
Oil pump
Inner rotor·to·outer rotor clearance 0. 15 mm (0.006 in) max . 0.20 mm (0.008 in)
Outer rotor·to·body clearance 0.15-0.2 1 mm (0.006-0.008 in)
0.25 mm (0.010 in)
Rotor·te·cover clearance 0.02-0.08 mm (0.001-0.003 in) 0.12 mm (0.005 in)
Starter idle gear 1.0.
17 .010- 17 .034 mm (0.6697-0.6706 in) 17.12 mm (0.674 in)
Starter idle gear bushing 0 .0. 16.966- 16.984 mm (0.6684 -0.6687 in)
16.93 mm (0.667 in)
J.D .
14.000- 14.018 mm (0.5512-0 .551 9 in)
14.04 mm (0.553 in)
Kick starter pinion 1.0. 22.020-22.04 1 mm (0.8669-0.8679 in) 22. 12 mm (0.87 1 in)
Kick starter spindle 0.0.
21.959-2 1.980 mm (0.8645-0.8654 in) 21.91 mm (0.86:3 in)
Mainshaft·to-clu tch outer guide clearance 0.051 - 0.055 mm (0.0020-0 .0022 in) 0. 14 mm (0.006 in)
Countershaft (starter idle gear) 0 .0 .
13.982-14.000 mm (0.5505-0.5512 in)
13.96 mm (0.550 in)
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