Clutch Lever Assembly Installation

the clutch lever holder so that the mating surface
• Install
[A] of the clutch lever clamp is aligned with the punch mark

•

[B] of the handlebar.
Tighten the upper clamp bolt first, and then the lower
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
Torque - Clutch Lever Clamp Bolts: 9.0 N·m (0.92 kgf·m, 80
in·lb)

CLUTCH 6-7
Clutch Lever and Cable
Clutch Lever Removal

the upper end of the clutch cable (see Clutch
• Remove
Cable Removal).
the clutch lever clamp bolts.
• Loosen
Remove:
• Starter Lockout Switch Screws [A]
Starter Lockout Switch [B]

• Remove:
Clutch Lever Pivot Locknut [A]
Clutch Lever Pivot Bolt
Clutch Lever [B]

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.
silicone grease to the clutch lever collar [A].
• Apply
Replace
clutch lever pivot locknut [B] with a new one.
• Install thetheclutch
[C] and clutch lever pivot bolt [D].
• Tighten the clutchlever
lever locknut securely.
•

6-8 CLUTCH
Clutch Lever and Cable
a non-permanent locking agent to the starter lock• Apply
out switch screws [A].
the starter lockout switch [B].
•○Install
Take care not to damage a pin [C] when installing the

•
•
•
•
•

starter lockout switch.
Tighten the starter lockout switch screws securely.
Tighten the clutch lever clamp bolts (see Clutch Lever
Holder Installation).
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.

CLUTCH 6-9
Clutch Cover
Clutch Cover Removal

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

Clutch Cover Installation

a cleaning fluid, clean off any oil or dirt that may be
• Using
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 that the dowel pins [B] are in position.
• Be
• Replace the clutch cover gasket with a new one.
the clutch cover bolts by following the sequence
• Tighten
numbers [1  15].
Bracket [A]
Clamp [B]
Torque - Clutch Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

6-10 CLUTCH
Clutch Cover
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.

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.
• Install the washer [B] and spring [C].
the release shaft straight into the upper hole of the
• Insert
clutch cover.

NOTICE
When inserting the release shaft, be careful not to
remove the spring of the oil seal.

• Fit the spring [A] as shown.
Clutch Cover Disassembly

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

• Remove:
Clutch Cover Plate Bolts [A]
Clutch Cover Plate [B]
Pad [C]
Needle Bearings [D]

CLUTCH 6-11
Clutch Cover
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.
the needle bearings [A] and oil seal [B] position as
• Install
shown.

○Press the upper and lower bearings so that the bearing
surface [C] is flush with the housing end of clutch cover.
○Press the oil seal so that the oil seal surface is flush with
the housing end of the clutch cover.
Apply grease to the oil seal lips.

•
• Install:
Pad [A]
•
•

Clutch Cover Plate [B]
Apply a non-permanent locking agent to the clutch cover
plate bolts [C].
Tighten:
Torque - Clutch Cover Plate Bolts: 10 N·m (1.0 kgf·m, 89
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

• Remove:
Clutch Cover (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs (with Clutch Spring Holders)
Clutch Spring Plate [B]
Pusher [C]

• Remove:
Friction Plates (10) [A]
Steel Plates (9) [B]
Spring [C]
Spring Seat [D]

the sub clutch hub [A] steady with the clutch holder
• Hold
[B], and remove the clutch hub nut [C].
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:
Torque Limiter Springs [A]
Sub Clutch Hub [B]
Clutch Hub [C]
Spacer [D]
Remove
the sub clutch hub bolts [E] as necessary.
○

•

If the oil pump drive gear is to be disassembled, loosen
the oil pump drive gear bolt [A] (left-hand threads).
Remove the clutch housing [B].

• Remove:
Needle Bearing [A]
Sleeve [B]

Clutch Installation

the clutch housing [A].
•○Install
Fit the holes [B] and projections [C].

○Engage the clutch housing gear and the crankshaft primary gear.

6-14 CLUTCH
Clutch
engine oil to the needle bearing [A] and the sleeve
• Apply
[B].
• Install:
Needle Bearing
Sleeve

the spacer [A] and the clutch hub [B].
•○Install
Face the stepped side [C] of the spacer to outside.

If the sub clutch hub bolts were removed, install them as
follows.
○Apply a non-permanent locking agent to the threads of
the sub clutch hub bolts, and tighten them.
Torque - Sub Clutch Hub Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

the clutch sub clutch hub [A].
•○Install
Align the damper cams [B] of the sub clutch hub to the
cam followers [C] of the clutch hub [D].
the four torque limiter springs as shown.
• Install
the first torque limiter spring [A].
• Install
Tang [B]

the second torque limiter spring [A].
• Install
Tang [B]

CLUTCH 6-15
Clutch
the third torque limiter spring [A].
• Install
Tang [B]

the fourth torque limiter spring [A].
• Install
Tang [B]

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: 130 N·m (13.3 kgf·m, 95.9 ft·lb)

the following as shown.
• Install
Friction Plates (48 Lining Blocks) [#1, #10]

Friction Plates (36 Lining Blocks) [#2  #9]
Steel Plates (T = 2.9 mm, 0.11 in.) [#1  #7]
Steel Plates (T = 2.6 mm, 0.10 in.) [#8, #9]
Spring Seat [A]
Spring [B]

NOTE

○The lining blocks [C] of the friction plate [#1, #10] are

smaller than them of the friction plates [#2  #9].
○Install the spring seat and spring between first steel
plate and second steel plate.

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.

6-16 CLUTCH
Clutch
the last friction plate (48 lining blocks) [A] fitting the
• Install
tangs [B] in the grooves in the housing as shown.

molybdenum disulfide grease [A] to the pusher [B].
• Apply
Install
the pusher to the drive shaft.
•

engine oil to the ball bearing [A] on the spring plate.
• Apply
Align
the
[B] of the spring plate to the grooves
• [C] of theprojections
sub clutch hub to install the spring plate on the

•

sub clutch hub.
Install the clutch springs and spring holders, and tighten
the clutch spring bolts.
Torque - Clutch Spring Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

• Install the clutch cover (see Clutch Cover Installation).
Spring Plate Free Play Measurement
Insufficient clutch free play will cause the engine braking
effect to be more sudden, resulting in rear wheel hop. On
the other hand, if the free play is excessive, the clutch lever
may feel “spongy” or pulsate when pulled.
Hold an extra drive shaft in a vise and install the following
clutch parts on the shaft (see Clutch Installation).
Collar [A]
Needle Bearing [B]
Sleeve [C]
Clutch Housing [D]
Spacer [E]
Clutch Hub [F]
Sub Clutch Hub [G]
Friction Plates (48 Lining Blocks) [H] (#1, #10)
Steel Plates (T = 2.9 mm, 0.11 in.) [I] (#1  #7)
Spring Seat [J]
Spring [K]
Friction Plates (36 Lining Blocks) [L] (#2  #9)
Steel Plates (T = 2.6 mm, 0.10 in.) [M] (#8, #9)
Clutch Spring Plate [N]

•

CLUTCH 6-17
Clutch
the clutch hub with the sub clutch hub.
• Engage
To
measure
play, set a dial gauge [A] against the
• raised centerthe[B]free
of the clutch spring plate.
Move
the
clutch
housing
gear back and forth [C]. The dif• ference between the highest
and lowest gauge readings

•

is the amount of free play.
Drive Shaft [D]
Measure the spring plate free play.
Spring Plate Free Play
Usable Range: 0.05  0.70 mm (0.002  0.028 in.)

If the free play is not within the usable range, change all
of the friction plate and measure the free play again.
If the free play is not within the usable range, adjust the
free play (see Spring Plate Free Play Adjustment).

Spring Plate Free Play Adjustment
NOTE

○The free play adjustment is performed by replacing the
steel plate(s).
the clutch spring plate free play (see Clutch
• Measure
Spring Plate Free Play Measurement), and then replace
the steel plate(s) which brings the free play within the
usable range.
Spring Plate Free Play
Usable Range:
0.05  0.70 mm (0.002  0.028 in.)

○Replace the following steel plate(s).
Thickness

Part Number

2.3 mm (0.090 in.)

13089-0008

2.6 mm (0.102 in.) (STD)

13089-0009

2.9 mm (0.114 in.)

13089-1093

NOTE

○Do not use the steel plate of 2.3 mm (0.090 in.) and 2.9
mm (0.114 in.) thickness at the same time.

6-18 CLUTCH
Clutch
Clutch Plate Assembly Length (Reference Information)
Assemble the following parts.
Clutch Hub [A]
Spring Seat [B]
Spring [C]
Sub Clutch Hub [D]
Sub Clutch Hub Bolts [E]
New Friction Plates [F]
Steel Plates [G]
Spring Plate [H]
Clutch Springs [I]
Clutch Spring Holders [J]
Clutch Spring Bolts [K]

•

Torque - Clutch Spring Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

• Measure the clutch plate assembly length [L].
Clutch Plate Assembly Length (Reference)
Standard: 53.5 mm (2.11 in.)

NOTE

○The length of the clutch plate assembly changes by the
steel plate thickness.

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 (0.012 in.)

Clutch Spring Inspection
If all the components are good, but the problem still exists, replace the clutch springs (see Clutch Removal and
Clutch Installation).

CLUTCH 6-19
Clutch
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.

Damper Cam Inspection

the clutch (see Clutch Removal).
• Remove
inspect the damper cams [A], cam followers [B],
• Visually
and the torque limiter springs [C].
• Replace the part if it appears damaged.

ENGINE LUBRICATION SYSTEM 7-1

Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
Engine Oil Flow Chart.............................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Engine Oil and Oil Filter..........................................................................................................
Oil Level Inspection...........................................................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Oil Pan....................................................................................................................................
Oil Pan Removal ...............................................................................................................
Oil Pan Installation ............................................................................................................
Oil Pressure Relief Valve........................................................................................................
Oil Pressure Relief Valve Removal ...................................................................................
Oil Pressure Relief Valve Installation ................................................................................
Oil Pressure Relief Valve Inspection.................................................................................
Oil Pump.................................................................................................................................
Oil Pump Removal ............................................................................................................
Oil Pump Installation .........................................................................................................
Oil Pump Drive Gear Removal/Installation .......................................................................
Oil Pump Drive Gear Installation.......................................................................................
Oil Pump Drive Gear Shaft Removal ................................................................................
Oil Pump Drive Gear Shaft Installation .............................................................................
Oil Cooler................................................................................................................................
Oil Cooler Removal...........................................................................................................
Oil Cooler Installation........................................................................................................
Oil Pressure Measurement.....................................................................................................
Oil Pressure Measurement ...............................................................................................
Oil Pressure Switch ................................................................................................................
Oil Pressure Switch Removal ...........................................................................................
Oil Pressure Switch Installation ........................................................................................

7-2
7-4
7-5
7-6
7-7