Honda CRF250R 2005, Owner'S Manual

Page: 55 / 164

Servicing Your Honda
51
Clutch System
Clutch Disc Inspection
Replace the clutch discs (1) if they show signs of
scoring or discoloration.
Measure the thickness of each clutch disc.
Service Limit:
0.112 in (2.85 mm)
Replace the clutch discs and clutch plates as an
assembly.
(1) clutch disc
Clutch Spring Inspection
(1) clutch spring
Measure the free length of each spring.
Service Limit:
1.46 in (37.2 mm)
If one or more springs are beyond the service
limit, replace the springs as a set.
Clutch Disc/Plate Installation
1. Coat the clutch plates (1) with transmission
oil.
2. Install the eight clutch discs (2) and seven
clutch plates alternately, starting with a clutch
disc.
(1) clutch plates (2) clutch discs
3. Apply grease to the clutch lifter rod (3).
4. Insert the clutch lifter rod into the mainshaft.
5. Install the clutch lifter (4) onto the rod.
(3) clutch lifter rod (4) clutch lifter
6. Install the clutch pressure plate (5).
7. Install the five clutch springs and bolts (6).
8. Tighten the bolts in a crisscross pattern in 2 or
3 steps, to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
(5) clutch pressure plate (6) clutch spring bolts
9. Install a new O-ring (7) in the groove of the
clutch cover (8).
(7) O-ring (8) clutch cover
(1)
(1)
(2) (1)
(4)
(3)
(5)
(6)
(8)
(7)
(cont’d)
10. Install the cover by tightening the five cover
bolts to the specified torque:
7 lbf·ft (10 N·m, 1.0 kgf·m)