Honda 2005 CRF450R Owner's Manual page 56

Clutch Cover/Disc/Plate Removal
1. Drain the transmission oil (page 40).
2. Remove the rear brake pedal (1) by removing
its pivot bolt (2).
(2)
(1) rear brake pedal (2) pivot bolt
3. Remove the six clutch cover bolts (3) and
clutch cover (4).
(3)
(3) clutch cover bolts (4) clutch cover
4. Remove the six clutch spring bolts and
springs (5).
Loosen the bolts in a crisscross pattern in 2 or 3
progressive steps.
5. Remove the clutch pressure plate (6).
(5)
(1)
(5) clutch spring bolts/springs
(6) clutch pressure plate
6. Remove the washer (7), needle bearing (8),
clutch lifter (9) and clutch lifter rod (10).
7. Remove the eight clutch discs and seven
clutch plates (11).
Assemble the clutch lifter, needle bearing and
washer. Turn the needle bearing with your
finger. The needle bearing should turn
smoothly and quietly. Replace the needle
bearing and washer if the needle bearing does
not turn smoothly.
(11)
(4)
(9)
(7) washer
(8) needle bearing
(9) clutch lifter
(6)
(8)
(7)
(10)
(10) clutch lifter rod
(11) clutch discs and plates
Clutch System
Clutch Disc/Plate Inspection
Replace the clutch discs (1) if they show signs of
scoring or discoloration.
Measure the thickness of each clutch disc.
Service Limit: 0.112 in (2.85 mm)
Replace the clutch discs and clutch plates as an
assembly.
(1)
(1) clutch disc
Check the clutch plate (2) for excessive warpage
or discoloration.
Check the plate warpage on a surface plate using
a feeler gauge.
Measure the thickness of the clutch plates.
Service Limit: 0.006 in (0.15 mm)
Replace the clutch discs and plates as a set.
(2) clutch plate
Servicing Your Honda
(2)
51