4. Maintenance
USE AND MAINTENANCE MANUAL
CHAPTER 4
MAINTENANCE
4-Strokes - Edition 00 / 2022
128
4
3
2
1
1
2
1
2
– Measure the distortion and thickness of the clutch disc,
using a reference plane “1” and a thickness gauge “2”;
– If not in accordance with specifications, replace the disc.
Distortion limit (XXF 250 / XEF 250): 0.20 mm (0.008
in)
Clutch disc thickness (XXF 250 / XEF 250):
1.50–1.70mm (0.059–0.067 in)
Distortion limit (XXF 450 / XEF 450):
0.10 mm (0.004 in)
Clutch installation
– Install the clutch housing “1”, spacer “2”, hub “3” and lock
washer “4”;
Install washer “4” with the “OUT” reference facing
outwards. (XXF 250 / XEF 250)
Install washer “4” by aligning its retainers with the
ribs of the clutch hub. (XXF 450 / XEF 450)
– Install nut “1”, lock the clutch hub with universal locking
tool “2” and tighten the nut to the specified torque;
Nut (clutch boss) (XXF 250 / XEF 250):
95 Nm (9.5 m•kg, 70 ft•lb)
Nut (clutch boss) (XXF 450 / XEF 450):
75 Nm (7.5 m•kg, 55 ft•lb)
Apply engine oil to the thread and contact surfaces of
the clutch hub nut.
– Measure the thickness of friction discs 1 and 2. If not in
accordance with specifications, replace the disc;
Friction disc thickness (XXF 250):
2.70–2.90mm (0.106–0.114 in)
Minimum limit: 2.60 mm (0.102 in)
Friction disc 1 thickness (XEF 250):
2.70–2.90mm (0.106–0.114 in)
Minimum limit: 2.60 mm (0.102 in)
Friction disc 2 thickness (XEF 250):
2.72–2.88mm (0.107–0.113 in)
Minimum limit: 2.62 mm (0.103 in)
Friction disc 1 thickness (XXF 450 / XEF 450):
2.92–3.08mm (0.115–0.121 in)
Minimum limit: 2.82 mm (0.111 in)
Friction disc 2 thickness (XXF 450 / XEF 450):
2.92–3.08mm (0.115–0.121 in)
Minimum limit: 2.82 mm (0.111 in)
