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2. Check the clearance between outer rotor
and inner rotor.
Standard clearance:
0.03 - 0.09 mm (0.0012 - 0.0035 in)
M. Clutch
1. Clutch housing
Check dogs on clutch housing. Look for
cracks and signs of galling on edges. If
damage is moderate, deburr. If severe, re-
place clutch housing.
NOTE:
Galling on the friction plate dogs of the
clutch housing will cause erratic clutch
operation.
2. Clutch boss
Check splines on clutch boss for galling. If
damage is slight to moderate, deburr. If it
is severe, replace clutch boss.
NOTE:
Galling on clutch plate splines will cause
erratic clutch operation.
3. Friction and clutch plates
Check clutch steel plates and friction
plates for heat damage. Measure friction
plate thickness at 3 or 4 points. Measure
clutch plates for warpage. Replace clutch
plate or friction plates as a set if any is
faulty or beyond wear limits.
Standard
3.0 mm
Friction plate
thickness
Clutch plate
warp limit
4. Clutch push rod
Check ends of clutch push rod for inden-
tation. If severe, clutch adjustment may
be difficult. Check for looseness of the
steel ends of the push rod. If ends are
loose or indented, replace push rod.
5. Clutch springs
Measure clutch spring free length. Replace
springs as a set if necessary.
N. Transmission
1.
Inspect each shift fork for signs of galling
on gear contact surfaces. Check for bend-
ing. Make sure each fork slides freely on
its guide bar.
Roll the guide bar across a surface plate.
2.
If bar is bent, replace.
Check the shift cam grooves for signs of
3.
wear or damage. If any profile has ex-
cessive wear and/or damage, replace cam.
Check the cam followers on each shift
4.
fork for wear. The follower should fit
snugly into its seat in the shift fork, but
should not be overly tight. Check the ends
that ride in the grooves in the shift cam. If
they are worn or damaged, replace
followers.
5.
Check shift cam dowel pins and side plate
for looseness, damage or wear. Replace as
required.
Check the shift cam stopper plate and cir-
6.
clip and stopper for wear. Replace as re-
quired.
7.
Check the transmission shafts using a
centering device and dial gauge. If any
shaft is bent beyond specified limit, re-
place shaft.
Wear limit
2.7 mm
(0.106 in)
0.05 mm
8.
Carefully inspect each gear. Look for
(0.002 in)
signs of obvious heat damage (blue dis-
coloration). Check the gear teeth for signs
of pitting, galling or other extreme wear.
Replace as required.
9.
Check to see that each gear moves freely
on its shaft.
Check to see that all washers and clips are
10.
properly installed and undamaged. Re-
place bent or loose clips and bent washers.
Clutch spring length:
34.6 mm (1.362 in)
Maximum run-out:
0.03 mm (0.001 in)
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