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EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information
has been complied to provide the mechanic with an easy to read, handy reference that contains com-
prehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
9 Bearings
Pitting/Damage¡ Replace.
EC084002
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.
2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
3. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessary
removal job.
6. For jobs requiring more information, the step-by-step format supplements 6 are given in addition
to the exploded diagram and job instruction chart.
1
CLUTCH AND PRIMARY DRIVEN GEAR
EC498200
PRIMARY DRIVEN GEAR, PUSH ROD AND PUSH LEVER AXLE
75 Nm (7.5 m•kg, 54 ft•lb)
1 Push rod and push lever axle removal
Extent of removal:
3 Primary driven gear removal
4
Extent of removal
Order
PRIMARY DRIVEN GEAR, PUSH
ROD AND PUSH LEVER AXLE
5
REMOVAL
1
Push rod 1
1
3
2
Circlip
2
3
Plain washer
4
Bearing
1
5
Push rod 2
6
Nut (clutch boss)
7
Lock washer
8
Clutch boss
3
9
Thrust plate [D=ø44mm (1.73 in)]
10
Primary driven gear
11
Bearing
12
Thrust plate [D=ø42mm (1.65 in)]
13
Bolt (push lever axle)
1
14
Push lever axle
ENG
6 Nm (0.6 m•kg, 4.3 ft•lb)
2 Push rod 1 disassembly
Part name
Q'ty
Remarks
1
1
1
1
1
1
Use special tool.
1
Refer to "REMOVAL POINTS".
1
1
1
1
1
1
1
4-33
CLUTCH AND PRIMARY DRIVEN GEAR
å
å
2
∫
3
ENG
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
9
Nut 1
9
Lock washer 2
9
Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4, 5 to hold the clutch boss.
Clutch holding tool:
YM-91042................................ 4 4
90890-04086............................5 5
å For USA and CDN
∫ Except for USA and CDN
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
9
Clutch housing 1
Cracks/Wear/Damage ¡ Replace.
9
Clutch boss 2
Scoring/Wear/Damage ¡ Replace.
EC484201
Primary driven gear
1. Check:
9
Circumferential play
Free play exists ¡ Replace.
9
Gear teeth a
Wear/ Damage ¡ Replace.
EC484400
Clutch spring
1. Measure:
9
Clutch spring free length a
Out of specification ¡ Replace springs as
a set.
Clutch spring free length:
Standard
<Limit>
44.0 mm
42.0 mm
(1.732 in)
(1.654 in)
4-34
6
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