Clutch and Shifter Reassembly

5. Clutch assembly

a. Install the thrust plate onto the transmission main axle.

1. Thrust plate

b. Install the oil pump drive sprocket onto the main axle without the spacer collar and place the oil pump drive chain on its sprocket.

1. Oil pump drive sprocket

c. Insert the spacer collar into the oil pump drive sprocket.

1. Spacer collar

d. Install the primary driven gear (clutch housing) without the bearing and inner spacer.

CAUTION:

Be sure that the oil pump drive gear tabs engage the clutch housing grooves on it's back or the tabs will be damaged when tightening the clutch boss securing nut.

e. Installing the primary driven gear bearing and inner spacer into the clutch housing.

1. Driven gear bearing 2. Inner spacer

f. Install the large thrust plate and clutch boss onto the main axle.

g. Install a new lock washer and nut and tighten the nut to the specified torque. Use the clutch boss holder (special tool).

1. Clutch boss holder

Tightening torque: 7.2 m-kg (52 ft-lb)

h. Bend the lock washer tabs along the nut flats.

1. Lock tab

i. Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.

j. Install the plate washer, thrust bearing, and clutch pull rod into the clutch pressure plate from inside.

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

k. Install the pressure plate assembly onto the clutch boss.

NOTE:

Pressure plate has a dot on it which must line up with the dot on clutch boss.

I. Install the clutch springs and screws. Tighten the screws.

Clutch screw torque: 1.0 m-kg (7.2 ft-lb)

m. Set the gear of the clutch pull rod on the pressure plate facing approximately 45° from horizontal toward the rear; set the clutch lever (if installed) on the right crankcase cover parallel to the gasket surface and install the cover to the crankcase. Do not forget to install two dowel pins.

n. If the clutch lever has been removed, install the lever return spring and lever on the shaft after installing the right crankcase cover. In this case make sure that the punch mark on the lever should align with the mark on the crankcase cover when pushing the lever towards the front by hand and then install the circlip.