Prepare sheet gum (chewing gum) or about 5 g clay [A].
Make an about 2.5 mm (0.098 in.) thick sheet [B] of gum
or clay, using a press and two thickness gauges [C] which
are overlapped to about 2.5 mm (0.098 in.).
Cut the sheet with scissors into four strips [D] of gum or
clay as shown.
Remove the clutch (see this chapter).
Place the inner clutch hub, spring holder assy [A], the
outer clutch hub [B], and the clutch plates (friction and
steel plates) [C] on blocks [D].
Do not support the spring holder [E] with the blocks.
Apply a soap and water solution to the strips. This is to
separate the strips easily from the clutch spring plate and
clutch hub when removing strips.
Place these four strips [A] on the raised surface [B] of the
outer clutch hub in a criss-cross pattern as shown.
Install the clutch spring plate [C] and a block [D].
While noting the positions of the spline teeth [E], fit the
clutch spring plate into the outer clutch hub smoothly. Be
careful not to move these strips.
Press [F] the block until the clutch plates [G] seat closely.
Do not press the block too much. This could dam-
age the clutch parts. The maximum press force is
100 kg (220 lb).
Remove the clutch spring plate.
Peel off these strips with a thin-bladed screwdriver.
Measure the pressed thickness [A] of each strip with
The thickness represents the spring plate gap.
Spring Plate Gap
Usable Range: 1.95 ~ 2.45 mm (0.0768 ~ 0.0965 in.)
In case of rear wheel hop, adjust the spring plate gap a
bit larger, and in case of clutch slip or "spongy" clutch
lever, adjust the gap a bit smaller within the usable