INSPECTION


1. INSPECT FORWARD CLUTCH DISC SET

Check the lining of all discs.
note
  • If the lining is flaking or discoloured, or if it is worn or the print mark is wearing away, replace the discs with a new one. When replacing, check the contact surfaces between the plate and the flange If they are scratched or discoloured, replace the discs, plates and the flanges with new ones.
  • Before replacing with new plates, soak them in ATF at least 2 hours.

2. CHECK FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
caution If the free length is smaller than the minimum, replace the forward clutch return spring sub-assembly.

Using vernier calipers, measure the free length of the forward clutch return spring sub-assembly.
Standard value: 26.74 mm
(For forward clutch return spring sub-assembly)

3. INSPECT DIRECT CLUTCH DISC SET

Check the lining of all discs.
note
  • If the lining is flaking or discoloured, or if it is worn or the print mark is wearing away, replace the discs with a new one. When replacing, check the contact surfaces between the plate and the flange If they are scratched or discoloured, replace the discs, the plates and the flanges with new ones.
  • Before replacing with new plates, soak them in ATF at least 2 hours.

4. INSPECT REVERSE CLUTCH DISC SET

Check the lining of all discs.
note
  • If the lining is flaking or discoloured, or if it is worn or the print mark is wearing away, replace the discs with a new one. When replacing, check the contact surfaces between the plate, the flange and the cushion plate If they are scratched or discoloured, replace the discs, the plates, the flanges and the cushion plate with new ones.
  • Before replacing with new plates, soak them in ATF at least 2 hours.

5. CHECK DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
caution If the free length is smaller than the minimum, replace the direct clutch return spring sub-assembly.

Using vernier calipers, measure the free length of the direct clutch return spring sub-assembly.
Standard value: 19.51 mm
(For direct clutch return spring sub-assembly)

6. CHECK REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
caution If the free length is smaller than the minimum, replace the reverse clutch return spring sub-assembly.

Using vernier calipers, measure the free length of the reverse clutch return spring sub-assembly.
Standard value: 21.04 mm
(For reverse clutch return spring sub-assembly)

7. CHECK INPUT SHAFT SUB-ASSEMBLY BUSH
caution Measure the inside diameter at different places and take an average. If the measurement is greater than the maximum, replace the input shaft sub-assembly bush with a new one.
When the input shaft sub-assembly bush is replaced, inspect the contact surface opposed to the intermediate shaft. If the surface is scratched or discoloured, replace the intermediate shaft with a new one.

Using a dial indicator, measure the inside diameter of the input shaft sub-assembly bush.
Standard value: Φ20.000 - 20.025 mm
(For input shaft sub-assembly bush)

8. CHECK DIRECT CLUTCH HUB SUB-ASSEMBLY BUSH
caution Measure the inside diameter at different places and take an average. If the measurement is greater than the maximum, replace the direct clutch hub sub-assembly with a new one.
When the direct clutch hub sub-assembly is replaced, inspect the contact surface opposed to the input shaft sub-assembly. If the surface is scratched or discoloured, replace the input shaft sub-assembly with a new one.

Using a dial indicator, measure the inside diameter of the direct clutch hub sub-assembly bush.
Standard value:
Front
Φ26.037 - 26.062 mm
Rear
Φ26.037 - 26.062 mm
(For direct clutch hub sub-assembly bush)

9. CHECK REVERSE CLUTCH HUB SUB-ASSEMBLY BUSH
caution Measure the inside diameter at different places and take an average. If the measurement is greater than the maximum, replace the reverse clutch hub sub-assembly with a new one.
When the reverse clutch hub sub-assembly is replaced, inspect the contact surface opposed to the direct clutch hub sub-assembly. If the surface is scratched or discoloured, replace the direct clutch hub sub-assembly with a new one.

Using a dial indicator, measure the inside diameter of the reverse clutch hub sub-assembly bush.
Standard value:
Front
Φ35.812 - 35.837 mm
Rear
Φ35.812 - 35.837 mm
(For reverse clutch hub sub-assembly bush)