5-way adjustable (to suit rider)
2  3 mm (0.08  0.12 in.)
(Reference)
45.6  46.4 mm (1.80  1.83 in.)
2.72  2.88 mm (0.107  0.113 in.)
0.15 mm (0.0059 in.) or less

Service Limit
– – –
– – –

– – –
2.6 mm (0.10 in.)
0.3 mm (0.01 in.)

CLUTCH 6-5
Special Tool and Sealant
Clutch Holder:
57001-1243

Liquid Gasket, TB1211F:
92104-0004

6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection

to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.

Clutch Lever Free Play Adjustment

to the Clutch Operation Inspection in the Periodic
• Refer
Maintenance chapter.

Clutch Cable Removal

• Remove:
Meter Cover (see Upper Fairing Removal in the Frame
•
•

chapter)
Right Middle Fairing (see Middle Fairing Removal in the
Frame chapter)
Slide the dust cover [A] at the clutch cable lower end out
of place.
Loosen the nuts [B], and slide the lower end of the clutch
cable to give the cable plenty of play.

the locknut [A] and screw in the adjuster [B].
• Loosen
Line
up
slots [C] in the clutch lever, locknut and ad• juster, andthethen
free the cable from the lever.
Free
the
clutch
inner cable tip from the clutch release
• lever.
• Remove the clutch cable out of the frame.

Clutch Cable Installation

the clutch cable correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
the clutch cable (see Clutch Operation Inspection
• Adjust
in the Periodic Maintenance chapter).
• Install the removed parts (see appropriate chapters).

Clutch Cable Lubrication

to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.

Clutch Lever Assembly Installation

the clutch lever so that the mating surface [A] of the
• Install
clutch lever clamp is aligned with the punch mark [B].
the upper clamp bolt first, and then the lower
• Tighten
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
Torque - Clutch Lever Clamp Bolts: 11 N·m (1.1 kgf·m, 97
in·lb)

CLUTCH 6-7
Clutch Lever and Cable
Clutch Lever Removal

the upper end of the clutch cable (see Clutch
• Remove
Cable Removal).
• Remove:
Starter Lockout Switch Screws [A]
Starter Lockout Switch [B]
Clutch Lever Pivot Locknut [C]
Clutch Lever Pivot Bolt
Clutch Lever [D]

Clutch Lever Installation

WARNING
If the starter lockout switch pin has been damaged
the starter lockout system will not work properly.
This allows the motorcycle to be started in gear with
the clutch lever released (clutch engaged), creating
sudden forward movement that can result in an accident or injury.
Check that the starter lockout switch operates properly when installing the clutch lever.
a silicone grease to the clutch lever collar.
• Apply
Replace
clutch lever pivot locknut [A] with a new one.
• Install thetheclutch
[B] and clutch lever pivot bolt.
• Tighten the clutchlever
lever
securely.
• Apply a non-permanent locknut
• out switch screws [C]. locking agent to the starter lockthe starter lockout switch [D].
•○Install
Take care not to damage a pin [E] when installing the

•
•
•
•

starter lockout switch.
Tighten the starter lockout switch screws securely.
Install the upper end of the clutch cable (see Clutch Cable
Installation).
Adjust the clutch cable (see Clutch Operation Inspection
in the Periodic Maintenance chapter).
Check that the pin of the starter lockout switch moves
smoothly.

WARNING
Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch
outer cable is fully seated in its fitting, or it could
slip into place later, creating enough cable play to
prevent clutch disengagement.

6-8 CLUTCH
Clutch Lever and Cable
Clutch Lever Position Adjustment
The adjuster has 5 positions so that the clutch lever position can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A] to align
the number with the mark [B] on the lever holder.
○The distance from the grip to the lever is minimum at number 5 and maximum at number 1.

•

CLUTCH 6-9
Clutch Cover
Clutch Cover Removal

the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
the clutch cable lower end (see Clutch Cable
• Disconnect
Removal).
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Clutch Cover Bolts [A]
the release lever [A] counterclockwise as shown,
• Turn
and remove the clutch cover [B].
About 90° [C]

Clutch Cover Installation

a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them

•

with a clean cloth.
Apply liquid gasket to the area [A] where the mating surface of the crankcase touches the clutch cover gasket.
Sealant - Liquid Gasket, TB1211F: 92104-0004

sure to dowel pins [B] are in position.
• Be
the clutch cover gasket with a new one and install
• Replace
it.
the clutch cover [A]
• Install
Tighten
the clutch cover bolt following the specified tight• ening sequence
[1  13].
Torque - Clutch Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

• Install the removed parts (see appropriate chapters).

Release Shaft Removal
NOTICE
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required.
the clutch cover (see Clutch Cover Removal).
• Remove
Pull
the
release
lever and shaft assembly [A] straight out
• of the clutch cover.

6-10 CLUTCH
Clutch Cover
Release Shaft Installation

grease to the oil seal lips on the upper ridge of the
• Apply
clutch cover.
engine oil to the needle bearings in the hole of the
• Apply
clutch cover.
molybdenum disulfide grease to the pusher-holding
• Apply
portion [A] on the release shaft.
the washer [B] and spring [C].
• Install
Insert
the
release shaft straight into the upper hole of the
• clutch cover.

NOTICE
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
the spring [A] as shown.
• FitRelease
Shaft [B]
Clutch Cover [C]

Clutch Cover Disassembly

• Remove:
Release Lever and Shaft Assembly (see Release Shaft
Removal)
Oil Filler Plug [A]
Oil Seal [B]
Needle Bearing [C]

remove the clutch cover plate bolt [A] and
• Ifthenecessary,
clutch cover plate [B].

CLUTCH 6-11
Clutch Cover

• Remove:
Needle Bearing [A]
Oil Level Inspection Window [B]

Clutch Cover Assembly

• Replace the needle bearings and oil seal with new ones.
NOTE

○Install the needle bearings so that the manufacture’s
mark face out.
soap and water solution to the oil seal.
• Apply
Install
• shown.the needle bearings [A] and oil seal [B] position as

○Press [C] the needle bearing so that the bearing surface
[D] is flush with the housing end [E] of clutch cover.
○Press the oil seal until the bottom.
Apply grease to the oil seal lips and the inner circumference of the oil seal.

•

soap and water solution to the rubber portion [A] of
• Apply
the oil level inspection window.
the oil level inspection window until the bottom so
• Press
that its projection [B] faces inside of the clutch cover [C].

•
•

If the damper removed, apply the non-permanent locking
agent to the clutch cover plate bolt.
Install the clutch cover plate.
Tighten:
Torque - Clutch Cover Plate Bolt: 4.0 N·m (0.41 kgf·m, 35
in·lb)

the O-ring [A] of the oil filler plug [B] with a new
• Replace
one.
grease to the new O-ring.
• Apply
Tighten:
•
Torque - Oil Filler Plug: Hand-tighten

6-12 CLUTCH
Clutch
Clutch Removal

the clutch cover (see Clutch Cover Removal).
• Remove
the three clutch spring bolts [A] alternately with
• Loosen
little by little (1/4 turn at a time) to prevent tilting the clutch
stopper plate [B].

NOTICE
Do not loosen the one or two clutch stopper bolt at
once to prevent clutch stopper plate from warpage
by the spring force.

• Remove:
Clutch Spring Bolts [A]
•

Clutch Stopper Plate [B]
Clutch Springs [C]
Visually inspect the clutch stopper plate.
If the clutch stopper plate is warped, replace it with a new
one.

• Remove:
Spring Seats [A]
Clutch Pressure Plate [B] (with Shim, Bearing and
Pusher [C])
Friction Plates and Steel Plates

the sub clutch hub [A] steady with the clutch holder
• Hold
[B], and remove the nut [C] and washers.
Special Tool - Clutch Holder: 57001-1243

○Use the clutch holder with sharpened hook nose by grinding.
Special Tool - Clutch Holder: 57001-1243

○Grind the hook nose by 0.5 mm (0.02 in.) as shown.

CLUTCH 6-13
Clutch

• Remove:
Clutch Hub [A]
Spacer [B]

the two 4 mm (0.16 in.) bolts [A], pull out the sleeve
• Using
[B], needle bearing [C] and clutch housing [D].
• Remove the spacer.

Clutch Installation

the spacer [A] so that the tapered side [B] faces
• Install
inward.

the clutch housing gear [A] and oil pump drive
• Engage
gear [B] with the crankshaft primary gear [C] and oil pump
drive gear [D].

engine oil to the sleeve [A] and needle bearing [B].
• Apply
Install
• Install:the sleeve so that the holes face outward.
• Needle Bearing
Spacer [C]

6-14 CLUTCH
Clutch

• Install:
Clutch Hub
•

Washer [A]
Install the washer [B] so that the “OUT SIDE” [C] mark
faces outward.

the clutch hub nut [A] with a new one.
• Replace
Hold
the
sub clutch hub [B] steady with the clutch holder
• [C], and tighten
the clutch hub nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 135 N·m (13.8 kgf·m, 100 ft·lb)

the friction plates [A] [B] and steel plates [C] alter• Install
nately as shown.
Friction Plates with large lining blocks [A]
Friction Plates with small lining blocks [B]
Thick Steel Plate [D]

NOTICE
If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.

○Install the last friction plate and steel plate later with the
clutch pressure plate.

molybdenum disulfide grease to the pusher end [A].
• Apply
Install
the bearing [B] and shim [C] to the pusher.
• Install the
pusher to the drive shaft [D] direction as shown.
•

CLUTCH 6-15
Clutch
the last friction plate [A] and steel plate [B] on the
• Put
clutch pressure plate [C] and install them.

the last friction plate so that the tangs [A] fit into the
• Install
grooves in the housing as shown.

NOTE

○Make sure that the clutch pressure plate is installed
without a gap.

sure to install the spring seats [A] on the clutch pres• Be
sure plate.

• Install:
Clutch Springs [A]
Clutch Stopper Plate [B]
Tighten the three clutch spring bolts [C] by hand until they
just begin to press each clutch spring.
○Hold the clutch pressure plate by hand while tightening
the clutch stopper bolts.

•

the three clutch spring bolts [A] alternately with
• Tighten
little by little (1/4 turn at a time) to prevent tilting the clutch
stopper plate [B].

NOTICE
Do not tighten the one or two clutch stopper bolt
at once to prevent the clutch stopper plate from
warpage by the spring force.

• Tighten:
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Install the clutch cover (see Clutch Cover Installation).

6-16 CLUTCH
Clutch
Clutch Plate Assembly Length Inspection
the following parts.
• Assemble
Clutch Hub [A]
Friction Plates [B]
Steel Plates [C]
Clutch Pressure Plate [D]
Spring Seats [E]
Clutch Springs [F]
Clutch Stopper Plate [G]
Clutch Spring Bolts [H]
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Measure the clutch plate assembly length [I].
Clutch Plate Assembly Length
45.6  46.4 mm (1.80  1.83 in.)

If the length is not within the specified range, adjust the
length (see Clutch Plate Assembly Adjustment).

Clutch Plate Assembly Length Adjustment

the clutch plate assembly length, and then re• Inspect
place the steel plate(s) which brings the length within the

•

•

specified range.
Remove:
Clutch Spring Bolts
Clutch Stopper Plates
Clutch Springs
Clutch Pressure Plate
Spring Seats
Replace the following steel plate(s).
Thickness

Part Number

2.0 mm (0.079 in.)

13089-1073

2.3 mm (0.091 in.) (STD)

13089-1084

2.6 mm (0.102 in.)

13089-1115

NOTE

○Do not use the steel plate of 2.0 mm (0.079 in.) and 2.6
mm (0.102 in.) thickness at the same time.
○When adjusting the clutch plate assembly, install the
steel plate of 2.0 mm (0.079 in.) or 2.6 mm (0.102 in.)
thickness to the second or third from the clutch pressure
plate.
the removed parts, and inspect the clutch plate as• Install
sembly length.
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

CLUTCH 6-17
Clutch
Clutch Plate, Wear, Damage Inspection

inspect the friction and steel plates for signs of
• Visually
seizure, overheating (discoloration), or uneven wear.
the thickness of each friction plate [A] at several
• Measure
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard:
2.72  2.88 mm (0.107  0.113 in.)
Service Limit:

2.6 mm (0.10 in.)

Clutch Plate Warp Inspection

each friction plate or steel plate on a surface plate
• Place
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
Standard:
0.15 mm (0.0059 in.) or less
Service Limit:

0.3 mm (0.01 in.)

Clutch Housing Finger Inspection

inspect the clutch housing fingers [A] where the
• Visually
friction plate tangs [B] hit them.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.

Clutch Housing Spline Inspection

inspect where the teeth [A] on the steel plates
• Visually
wear against the sub clutch hub splines [B].
If there are notches worn into the splines, replace the sub
clutch hub. Also, replace the steel plates if their teeth are
damaged.

6-18 CLUTCH
Clutch
Clutch Pressure Plate and Clutch Hub Inspection

inspect the contact areas [A] of the clutch pres• Visually
sure plate [B] and clutch hub [C] for damage.
If the contact areas are damaged replace them with new