Installation

Pinion Assembly/Clutch Armature/Clamp

Clutch Armature

1.Lay two stacks of two dimes on smooth bench sur- face.

2.Lay armature (25) on two stacks of dimes.

3.Press center of hub (26) down to bench surface.

25	26	0.12+01 in (3.0+.25 mm)
		0.12+01 in (3.0+.25 mm)

ti6321a

dimes

4.Install armature (25) on engine drive shaft.

5.Install four screws (23) and lock washers (24) with torque of 125 in-lb.

Pinion Assembly

1.Check o-ring (29d) and replace if missing or dam- aged.

2.Tap pinion shaft (29a) in with plastic mallet.

3.Install retaining ring (29b) with beveled side facing up.

4.Place pinion assembly on bench with rotor side up.

5.Apply thread sealant to screws. Install four screws (28) and lock washers (24). Alternately torque screws to 125 in-lb until rotor is secure. Use threaded holes to hold rotor.

6.Install pinion assembly (29) with four screws (36) and washers (37).

7.Connect clutch cable connectors to inside of pres- sure control.

Clamp Removal

1.Remove engine.

2.Drain gasoline from tank according to Honda man- ual.

3.Tip engine on side so gas tank is down and air cleaner is up.

4.Loosen two screws (24) on clamp (22),

5.Push screwdriver into slot in clamp (22) and remove clamp.

ti6199a

Clamp Installation

1.Install engine shaft key (18).

2.Tap clamp (22) onto engine shaft (A). Maintain dimension shown note 2. Chamfer must face engine.

3.Check dimension: Place rigid, straight steel bar (B) across face of clutch housing (19). Use accurate measuring device to measure distance between bar and face of clamp. Adjust clamp as necessary. Torque two screws (24) to 125 ±10 in-lb (14 ±1.1 N·m).

1Face of clutch housing

21.550 ± .010 in. (39.37 ± .25 mm) - GMAX 3900

2.612 ± .010 in. (66.34 ± .25 mm) - GMAX 5900 & 7900

3Torque to 125 ±.10 in-lb (14 ±1.1 N·m)

4Chamfer this side

	19




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TIA

3A0243A