Installation
Clutch Armature
1.FIG. 8. Lay two stacks of two dimes on smooth bench surface.
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) |
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ti6321a
dimes
FIG. 8
Pinion Assembly/Clutch Armature/Clamp
4.Install armature (25) on engine drive shaft.
5.Install four screws (23) and lock washers (24) with torque of 125
Pinion Assembly
6.FIG. 6. Check o-ring (29d) and replace if missing or damaged.
7.Tap pinion shaft (29a) in with plastic mallet.
8.Install retaining ring (29b) with beveled side facing up.
9.FIG. 5. Place pinion assembly on bench with rotor side up.
10.Apply Loctite® 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.
11.FIG. 4. Install pinion assembly (29) with four screws (36) and washers (37).
12.FIG. 14. Connect clutch cable connectors to inside of pressure control.
Clamp Removal
1.Do Engine Removal.
WARNING
Gasoline can spill and cause a fire or explosion if engine is tipped on side.
2.Drain gasoline from tank according to Honda manual.
3.FIG. 9. Tip engine on side so gas tank is down and air cleaner is up.
4.FIG. 10. Loosen two screws (24) on clamp (22),
5.Push screwdriver into slot in clamp (22) and remove clamp.
ti6199a
FIG. 9
Clamp Installation
1.FIG. 10. 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
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TIA
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FIG. 10
310893L | 11 |
