Section 03
ENGINE
Subsection 10
(CLUTCH)
03-10-2
VMR2004_014_03-10A.FM
GENERAL
At installation, use torque values and Loctite prod-
ucts from the exploded view. Clean threads before
using Loctite products when installing screws.
NOTE:
For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not nec-
essary to remove engine from vehicle.
Always disconnect the negative wire from the bat-
tery before working the engine.
When the repair is done. Test drive to confirm all
is working well. If the test drive is good, perform
a change of engine oil.
CLUTCH ADJUSTMENT
The clutch adjustment is necessary after any works
in the clutch system.
Loosen cable tension.
Adjust clutch release mechanism.
The release lever must locate on the spline in such
a way that dimension A is obtained. See the fol-
lowing illustration.
NOTE:
If necessary, unscrew the Allen socket
screw and remove release lever. Replace the lever
at the appropriate position then tighten socket
screw to 8 N•m (71 lbf•
in
).
A. 68 to 75 mm (2-11/16 to 2-31/32 in)
Adjust cable free play.
A. 3.5 ± 0.5 mm (9/64 ± 1/64 in)
CLUTCH COVER
Removal
Drain engine oil and coolant.
Detach clutch cable.
Remove:
– LH footpeg
– shifting pedal
– water pump cover
– starter bolts
– all bolts retaining clutch cover
– clutch cover
no. 8
.
1. Footpeg
2. Shifting pedal
3. Water pump cover
4. Starter bolts
5. Clutch cover
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
V02D03A
A
V02D04A
A
V02D0EA
4
3
2
5
1
Summary of Contents for DS 650
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Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
