1. | Remove new friction discs from package. Soak in primary chaincase lubricant for a minimum of 5 minutes before installation. | |
2. | NOTE Clutch disassembly and assembly is the same for all Assist and Slip 9-plate and 10-plate clutches except for plate and disc count. | |
3. | Discard plates and friction discs removed from clutch. |
1. | Install new clutch plates and friction discs. See CLUTCH: ASSIST AND SLIP, Clutch Pack Only in the service manual. a. See Figure 1 for order of assembly. b. Install new coil springs (4) provided in kit. | |
2. | Install the primary cover. Fill housing with lubricant following the instructions in the service manual. |
1 | Bolt (3) |
2 | Stopper plate |
3 | Mainshaft nut |
4 | Coil spring (3) |
5 | Seat (3) |
6 | Pressure plate |
7 | Narrow friction plate (3) |
8 | Narrow steel plate (1) |
9 | Wide steel plate (8) |
10 | Wide friction plate (7) |
11 | Damper spring |
12 | Damper spring seat |
13 | Clutch hub |
14 | Clutch shell |
1. | Check hydraulic clutch fluid level. Adjust as needed. See BLEED CLUTCH CONTROL SYSTEM, Drain and Fill in the service manual. | |
2. | Check clutch lift. a. Measure release plate movement. See HYDRAULIC CLUTCH RELEASE BEARING AND PUSHROD, Measure Release Plate Movement in the service manual. | |
3. | Verify clutch interlock operation. Perform the following steps in order. Do not skip any steps. If any test fails, stop and diagnose the condition before proceeding. . a. Remove spark plug cables from spark plugs. b. Straddle vehicle. Press and hold the rear brake pedal. c. Turn ignition switch ON. Turn the run/stop switch to RUN. d. Shift into neutral and release the clutch lever. Briefly push the start switch. The starter should operate. e. Shift into the highest gear. Pull in the clutch lever and briefly press the start switch. The starter should operate. f. With the clutch lever released and transmission in gear, briefly press the start switch. The starter should not operate. g. Turn off the ignition and run/stop switches. h. Install spark plug cables |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | 10-plate clutch kit | 37000258 |
2 | Coil spring kit | 37000288 |