Clutch - Installation

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
    caution
    Make sure the oil pump drive chain is engaged with the oil pump drive gears. Running the engine without drive to the oil pump will stop oil supply to the engine. Running the engine without oil pressure will cause severe engine damage.
  1. Visually check the oil pump drive chain is engaged with the drive gears.
  2. Position the clutch outer drum assembly to the input shaft and align the oil pump sprocket drive pegs with the corresponding holes in the rear of the clutch outer drum.
    3. Clutch Align LG1_1 (ckxd)

    1. Clutch outer drum (rear view)

    2. Oil pump sprocket drive pegs

    3. Clutch outer drum sprocket drive holes

  3. While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive, refit the bearing.
    4. Clutch - bearing sleeve cixd D Series.svg)

    1. Bearing sleeve

    2. Needle roller bearing

    3. Shaft

    note
    When the bearing and sleeve are correctly fitted, it will be a flush fit with the clutch drum face.
  4. Fit the thrust washer to the shaft.
  5. Fit the clutch inner drum.
  6. Fit the flat washer, a new Belleville washer (OUT mark facing outwards), and a new centre nut.
    7. LG1 Clutch Inner Drum Install

    1. Thrust washer

    2. Clutch inner drum

    3. Flat washer

    4. Belleville Washer OUT Mark

    5. Centre nut

  7. Using service tool T3880307, lock the inner and outer drums together. Depress the rear brake pedal to prevent the engine rotating, and tighten the centre nut to 98 Nm.
  8. Remove service tool T3880307.
    9. Clutch Retaining Plate - Remove (ciwx_3)

    1. T3880307 - Clutch Anti-rotation Jig

  9. Disengage second gear and check for free rotation of the clutch inner drum.
  10. Using a suitable pin punch, stake the nut to the shaft.
    11. note
    Always refer to the Clutch Pack Height prior to fitting new clutch plates to the motorcycle.
  11. Coat all clutch friction plates in clean engine oil before fitting the friction plates, steel plates, anti-judder spring and anti-judder seat washer to the clutch basket in the same order and orientation as noted during removal.
    12. note
    The inner friction plate is different to the other friction plates. It must be fitted in its noted position.The inner and outer steel plates are different to the other plates. They must be fitted in their noted position.
    LG1 Clutch Plate Assembly

    1. Clutch outer drum

    2. Clutch inner drum

    3. Anti-judder seat washer

    4. Anti-judder spring

    5. Friction plate (inner)

    6. Steel plate (inner)

    7. Friction plates

    8. Steel plates

    9. Steel plate (outer)

    10. Pressure plate

  12. Refit the clutch pull rod.
  13. Ensure that the spring seats are fitted into the pressure plate as noted for removal.
  14. Fit the pressure plate to the clutch centre, making sure the three raised teeth on the pressure plate align with the three missing teeth sections on the clutch centre, and the three raised teeth on the clutch centre align with the three missing teeth sections on the pressure plate.
    15. LG1 Clutch Pressure Plate Alignment_1

    1. Raised teeth

    2. Missing teeth sections

    3. Clutch pressure plate

  15. Rotate the clutch pressure plate in a clockwise direction until it comes into contact with the ramps on the clutch centre and the bolt holes align.
    16. LG1 Clutch Pressure Plate Alignment_2

    1. Clutch pressure plate

    2. Alignment mark (1 of 3)

    3. Bolt hole (1 of 3)

    note
    There are spring seats located in the stopper plate. Ensure the seats are in the stopper plate prior to fitting the springs.
    caution
    Make sure the clutch stopper plate is tightened evenly. Failure to tighten the clutch stopper plate fixings as described may cause severe engine damage.
  16. Fit the springs and stopper plate. Install the fixings and tighten finger tight until resistance is felt against the springs on each fixing.
  17. Tighten the fixings to a maximum of three turns each in an alternating pattern. Continue until the stopper plate is fully down.
  18. Tighten the fixings to 5 Nm.
  19. Tighten the fixings to 10 Nm.
    20. Clutch Pressure Plate LG1_1

    1. Fixings

    2. Stopper plate

    3. Spring seats

    4. Springs

    5. Pressure plate

Perform the following operations

Perform the following operations:

Clutch Cover - Install L Series