311020
14
Installation
Clutch Armature
1. Fig. 8. Lay two stacks of two dimes on smooth
bench surface.
2. Lay armature (87) on two stacks of dimes.
3. Press center of clutch down on bench surface.
Fig. 8
87
8705A
0.12
±
.01 in. (3.0
±
.25 mm)
dimes
4. Install armature (87) on engine drive shaft.
5. Install four screws (175) and lockwashers (172)
with torque of 125 in-lb.
Pinion Assembly
6. Fig. 6. Check o--ring (25c) and replace if missing
or damaged.
7. Tap pinion shaft (25d) in with plastic mallet.
8. Install retaining ring (25e) with beveled side
facing up.
9. Fig. 5. Place pinion assembly on bench with rotor
side up.
10. Apply thread sealant to screws. Install four screws
(170) and lockwashers (172). Alternately torque
screws to 125 in-lb until rotor is secure. Use
threaded holes to hold rotor.
11. Fig. 4. Install pinion assembly (25) with five screws
(189) and lockwashers (188).
12. Fig. 11. Connect pump stroke sensor and clutch
cables.
13. Fig. 12. Install junction box (226) with clip (251).
Clamp
Removal
1. Do Engine Removal.
2. Drain gasoline from tank according to Honda
manual.
3. Tip engine on side so gas tank is down and air
cleaner is up.
4. Fig. 9. Loosen two screws (175) on clamp (82),
5. Push screwdriver into slot in clamp (82) and re-
move clamp.
Installation
1. Fig. 9. Install engine shaft key (88).
2. Tap clamp (82) on engine shaft (A) with plastic
mallet. Maintain dimension shown note 2. Chamfer
must face engine.
3. Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (5). Use accurate
measuring device to measure distance between bar
and face of clamp. Adjust clamp as necessary.
Torque two screws (175) to 125
±
10 in-lb (14
±
1.1
N
¡
m).
B
1
2
3
A
4
ti5484b
Fig. 9
1
3
2
Face of clutch housing
2.61
±
.010 in. (66.29
±
.25 mm); LineLazer lV 5900
Torque to 125
±
.10 in-lb (14
±
1.1 N
¡
m)
2.55
±
.010 in. (39.37
±
.25 mm); LineLazer lV 3900/R300
88
82
4 Chamfer this side
85
175
