Engine, clutch and transmission 2»31
Clutch plate pack guide
Model
No.
of plates
Order of fitting to clutch centre
1991-93 TDM
8 friction, 8 plain
start with the special 'slick' plain plate, then alternate friction and plain plates until ending
with special friction plate which has a slot in one of its tabs.
1994-95 TDM
8 friction, 8 plain
start with the special 'slick' plain plate, then alternate friction and plain plates.
1996-98 TDM and all TRX
9 friction, 8 plain
start with friction plate, then alternate plates until ending with a friction plate.
1999 TDM
9 friction, 8 plain
start with a special friction plate (black), then alternate plain and Motion plates until
ending with a special friction plate (black).
1989 XTZ
8 friction, 8 plain
special plain plate fitted as part of anti-judder assembly, then alternate friction and plain
plates, until ending with special friction plate which has a slot in one of its tabs.
1990-94 XTZ
8 friction, 8 plain
start with the special 'slick' plain plate, then alternate friction and plain plates until ending
with special friction plate which has a slot in one of its tabs.
1995 XTZ
8 friction, 8 plain
start with the special 'slick' plain plate, then alternate friction and plain plates.
indentations on the edges of the protruding tangs
of the friction plates and/or slots in the edge of
the housing with which they engage. Similarly
check for wear between the inner tongues of the
plain plates and the slots in the clutch centre.
Wear of this nature will cause clutch drag and
slow disengagement during gear changes, since
the plates will snag when the pressure plate is
lifted. With care a small amount of wear can be
corrected by dressing with a fine file, but if this is
excessive the worn components should be
renewed.
17 Inspect the sleeve and caged needle roller
bearing in conjunction with the clutch housing's
internal bearing surface. If there are any signs of
wear, pitting or other damage the affected parts
must be renewed.
18 Check the pressure plate, thrust bearing and
plate washer for signs of roughness, wear or
damage, and renew any parts as necessary.
19 On 1989 XTZ models, if removed, check the
clutch centre anti-judder assembly components
(consisting of the wire retainer ring, plain plate,
anti-judder spring and spring seat) for wear or
damage, and renew any parts as necessary.
20 Check the clutch operating mechanism in the
clutch cover for smooth operation. Check the
pinion and pullrod teeth for signs of damage. If
necessary, prise off the E-clip securing the pinion
to the actuating shaft, and withdraw the shaft
from the cover
(see
illustration).
Check the two needle roller
bearings for roughness, wear or damage. If they
need to be renewed, heat the cover in very hot
water to ease removal and drift them out. If the
shaft is removed, lever out the oil seal and renew
it. Clean all components and lubricate the seal
and bearings with grease.
Installation
21 Remove all traces of old gasket from the
crankcase and clutch cover surfaces. On 1989
XTZ models, if disassembled, reassemble the
clutch centre anti-judder assembly components,
fitting the spring seat, the anti-judder spring, the
plain plate and the wire retainer ring in that order.
22
On all except 1989 to 1991 XTZ models, fit
the thrust washer and the inner thrust plate onto
the shaft
(see illustrations).
On 1989 to 1991
XTZ models, fit the inner thrust plate onto the
shaft with its shouldered side inwards.
23 Lubricate the needle roller bearing and
sleeve with clean engine oil. Install the clutch
housing, without its needle roller bearing and
sleeve, and support it in position, making sure it
is engaged correctly with the primary drive gear
on the crankshaft
(see illustration).
24
Install the needle bearing and the sleeve into
the middle of the clutch housing
(see
illustrations).
25
Lubricate the outer thrust plate with clean
16.22b ... and inner thrust plate onto the
shaft
16.23 Slide the housing into place so that it
engages the primary drive gear...
16.24a ... then fit the needle bearing
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16.24b ... and the sleeve into the middle of
the housing
Staned by Stalker
16.22a Fit the thrust washer.
