Oil Pump and Clutch -- Inspection and Repair

J. Oil Pump

1. Check the clearance between housing and outer rotor.

Standard clearance:

0.09 ~ 0.15 mm

(0.0035 ~ 0.0059 in)

2. Check the clearance between outer rotor and inner rotor.

Standard clearance

0.12 mm (0.005 in) or less

3. Check the plunger for scratches and wear.

1. Relief valve plunger

K. Clutch

1. Clutch housing

a. Check the dogs on the clutch housing. Look for cracks and signs of galling on edges. If damage is moderate, deburr. If severe, replace the clutch housing.

Galling on the friction plate dogs of the clutch housing will cause erratic clutch operation.

b. Check the clutch housing bearing for damage. If damaged replace bearing.

2. Clutch boss

a.   The clutch boss contains a built-in damper beneath the first clutch plate (clutch plate 2). It is not normally necessary to remove the circlip and disassemble the built-in damper unless there is serious clutch chattering.

b.   Check splines on clutch boss for galling. If damage is slight to moderate, deburr; if it is severe, replace clutch boss.

Galling on clutch plate splines will cause erratic 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 with a dial gauge and stand. Replace clutch plate or friction plates as a set if any is faulty or beyond wear limits.



Wear limit

Friction plate thickness

3.0 mm (0.12 in)

2.8 mm (0.11 in)

Clutch plate warp limit

0.05 mm (0.0020 in)

1. Feeler gauge

4. Clutch actuating mechanism

1. Plate washer 2. Thrust bearing 3. Pull rod

a.   Check the pull rod rack gear teeth for wear and damage, replace if damaged.

b.  Check the pull rod thrust bearing for damage, replace if damaged.

c.   Check the clutch lever shaft pinion gear teeth for damage, replace if damaged.

5. Clutch springs

Measure the clutch spring free length. Replace the springs as a set if any is less than minimum free length.

Clutch spring minimum length: 39.1 mm (1.539 in)