EAS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
CLUTCH
5-38
EAS20055
CLUTCH
Removing the clutch cover
Order Job/Parts to remove Q’ty Remarks
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-24.
.tcennocsiD1elbac hctulC1
1revoC2
3
O
2
sensor coupler bracket
1
1revoc hctulC4
1teksag revoc hctulC5
2nip lewoD6
1pac rellif liO7
1
2
3
4
5
6
7
6
(6)
12 N・m (1.2 kgf・m, 8.7 lb・ft)
12 N・m (1.2 kgf・m, 8.7 lb・ft)
12 N・m (1.2 kgf・m, 8.7 lb・ft)
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
7 N・m (0.7 kgf・m, 5.1 lb・ft)
CLUTCH
5-43
8. Remove:
• Clutch boss nut
• Conical spring washer
• Washer
• Clutch boss
• Thrust plate
• Clutch housing
• Oil pump drive chain
EAS30348
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
• Friction plate 1, 2
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• Friction plate 1, 2 thickness
Out of specification → Replace the friction
plates as a set.
TIP
Measure the friction plate at four places.
EAS30349
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• Clutch plate 1, 2
Damage → Replace the clutch plates as a
set.
2. Measure:
• Clutch plate 1, 2 thickness
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch
plates as a set.
3. Measure:
• Assembly width “a” of the friction plates and
clutch plates
Friction plate 1 thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
Friction plate 2 thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
2
1
3
A. Friction plate 1
B. Friction plate 2
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
Clutch plate 1 thickness
2.20–2.40 mm (0.087–0.094 in)
Warpage limit
0.10 mm (0.004 in)
Clutch plate 2 thickness
1.90–2.10 mm (0.075–0.083 in)
Warpage limit
0.10 mm (0.004 in)
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