15.11B ... And pull the sprockets and chain off as an assembly
Check the needle bearing in the clutch housing for signs of roughness or wear, and renew if necessary.Check the pressure plate for signs of roughness, wear or damage, and renew if necessary.
Check the anti-judder spring and spring seat for distortion, wear or damage, and renew them if necessary.
Check that the clutch release shaft rotates smoothly in the engine cover and that the return spring operates properly. With the pushrod in place, the spring should be under slight tension. If the action is rough or stiff, draw the shaft out of the cover and inspect and clean the bearing surfaces (see
15.14 Checking the plain plates for warpage
5&
15.15 Measuring clutch spring free length
2«26
Engine, clutch and transmission
15.22 Inspect the clutch release shaft and return spring
illustration). Check the condition of the spring - if it has lost its tension, renew it. 23 Renew the release shaft oil seal if it is damaged or deteriorated, or shows any signs
15.25a Install the clutch housing sleeve...
15.23a Prise oil seal (arrowed) out of case with a flat-bladed screwdriver...
of leakage (see illustration). Check the needle bearing in the engine cover for signs of roughness or wear and renew it if necessary (see illustration).
Installation
Remove all traces of old gasket from the crankcase and engine cover surfaces.
Smear the clutch housing sleeve with clean engine oil and slide the sleeve onto the transmission input shaft, followed by the oil pump drive sprocket, with its pins facing out, the chain and the pump sprocket as one assembly (see illustrations).
Locate the pump sprocket onto the pump shaft. Apply a drop of locking compound to the sprocket bolt and install the bolt. Lock the sprocket (see Step 11) and tighten the bolt to the torque setting specified at the beginning of this Chapter.
15.23B ... And check the condition of the needle bearing
Slide the clutch housing onto the sleeve on the input shaft, making sure that the teeth of the primary driven gear on the back of the housing engage fully with those of the primary drive gear, and that the pins on the oil pump drive sprocket engage with the slots in the back of the housing (see illustrations).
Slide the thrust washer onto the shaft (see illustration).
Fit the spring seat onto the clutch centre, followed by the anti-judder spring, making sure its outer edge is raised off the spring seat - if it is touching the seat and the inner edge is raised, it is the wrong way round (see illustrations).
Coat each clutch plate with engine oil, then build up the plates on the clutch centre, making sure the outermost friction plate and the innermost friction plate are correctly identified and fitted (see Step 8). Start with the
15.27a Engage pins on sprocket (A) in slots (B)...
15.27b ... by turning oil pump sprocket (arrowed)
15.29a Fit the spring seat (A) and the spring (B)...
15.29b ... so that the outer edge of the spring (arrowed) is off the seat
Engine, clutch and transmission 2»27
15.30b ... followed by a plain plate as described
15.31 Fit the pressure plate onto the back of the clutch
Fit the clutch pressure plate onto the back of the clutch centre (see illustration).
Turn the assembly over carefully and slide it into the clutch housing, making sure that the tabs on all except the outer friction plate align with the long slots in the housing and the tabs on the outer friction plate align with the short slots in the clutch housing (see illustration).
Slide on the Belleville washer with its OUTSIDE marking facing out, then fit a new clutch nut (see illustrations). Using the method employed on removal to lock the input shaft (see Step 6), tighten the nut to the torque setting specified at the beginning of this Chapter. Check that the clutch centre rotates freely after tightening, then stake the rim of the nut into the indent in the end of the shaft using a suitable punch (see illustrations).
Install the clutch springs, release plate and release plate bolts and tighten them evenly in a criss-cross sequence to the specified torque setting (see illustration).
Unscrew the 6 mm bolt from the primary drive gear (see illustration).
15.32 Align tabs on outer friction plate with short slots in clutch housing
15.33b Stake the rim (arrowed) of the clutch nut...
15.33a Fit a new clutch nut with the washer marking (arrowed) facing out
15.33c ... into the indent on the input shaft
15.34 Fit the springs, plate and bolts as described
15.35 Remove the bolt locking the primary drive gear halves together
2»28 Engine, clutch and transmission
15.36a Locate one end of the spring in the shaft (A), the other against the case (B)...
15.38a Locate a new gasket on the crankcase dowels (arrowed)...
If removed, install the clutch release shaft in the engine cover and locate the spring on the lower end of the shaft (see illustration). Apply some grease to the release pushrod, then turn the shaft until the pushrod seat is aligned and insert the pushrod (see Illustration).
Install the ignition pulse generator into the engine cover and tighten the bolts securely. Apply a smear of suitable sealant into the cutout in the cover and install the wiring grommet (see illustration).
If removed, insert the dowels in the crankcase. Install the engine cover using a new gasket, making sure it locates correctly onto the dowels, then install all the cover bolts with the clutch cable bracket (see illustrations). Tighten the bolts evenly in a criss-cross sequence.
If the engine is in the frame, fit the clutch