Honda CBR650 - Service manual > Clutch

REMOVAL

Remove the right crankcase cover.

Remove the thrust washer [1] and wave washer [2] from the starter idle gear.

Remove the starter idle gear [1] and shaft [2].

Remove the clutch spring bolts [1], springs [2] in a crisscross pattern in two to three steps, then remove the pressure plate [3].

Remove the clutch lifter piece [4] from the lifter bearing.

Remove the following:

• Clutch disc A [1]
• Five clutch discs [2]
• Six clutch plates [3]
• Clutch disc B [4]
• Judder spring [5]
• Spring seat [6]

Unstake the clutch center lock nut [1].

Hold the clutch center [1] with the special tool and remove the clutch center lock nut [2].

TOOL:
[3] Clutch center holder 07724-0050002 or equivalent commercially available

Discard the lock nut.

Remove the lock washer [1], thrust washer [2] and clutch center [3].

Remove the thrust washer [1] and clutch outer [2].

Remove the needle bearing [1].

Remove the bolt [1] and oil pump drive chain guide [2].

Remove the oil pump driven sprocket washer-bolt [1].

Remove the oil pump drive sprocket [2], driven sprocket [3] and drive chain [4] as an assembly.

Remove the clutch outer guide [1].

INSPECTION

Inspect the following parts for scratch, damage, abnormal wear and deformation.

• Clutch lifter bearing
• Clutch lifter plate
• Clutch springs
• Clutch center
• Spring seat
• Judder spring
• Clutch discs/plates
• Clutch outer/primary driven gear/needle bearing
• Clutch outer guide
• Oil pump drive/driven sprocket
• Oil pump drive chain
• Mainshaft

Measure each part according to CLUTCH/GEARSHIFT LINKAGE/STARTER CLUTCH SPECIFICATIONS.

Replace any if it is out of service limit.

• Replace the clutch springs as a set.
• Replace the clutch discs and plates as a set.

INSTALLATION

Apply molybdenum oil solution to the clutch outer guide [1] sliding surface and install it to the mainshaft.

Apply oil to the oil pump drive sprocket [1] and driven sprocket [2] teeth.

Install the oil pump driven sprocket with its "OUT" mark [3] facing out.

Install the oil pump drive/driven sprocket and drive chain [4] as an assembly.

Apply a locking agent to the oil pump driven sprocket washer-bolt [5] threads.

Be careful not to drop the parts into the oil pan.

Install the oil pump driven sprocket bolt with the washer [6] and tighten the bolt to the specified torque.

TORQUE:15 N*m (1.5 kgf*m, 11 lbf*ft)

Be careful not to drop the parts into the oil pan.

Install the oil pump drive chain guide [1] by aligning the hole with boss of crankcase.

Tighten the bolt [2] securely.

Apply engine oil to the rotating area of the needle bearing [1].

Install the needle bearing onto the mainshaft.

Apply molybdenum oil solution to the clutch outer [1] gear and sliding surface.

Install the clutch outer by aligning the holes with the tabs of the oil pump drive sprocket.

Install the thrust washer [1].

Install the clutch center [1] and thrust washer [2].

Install the lock washer [3] with its "OUT" mark [4] facing out.

Apply engine oil to the threads and seating surface of a new clutch center lock nut [1], then install it onto the mainshaft.

Hold the clutch center [2] with the special tool and tighten the lock nut to the specified torque.

TOOL:
[3] Clutch center holder 07724-0050002 or equivalent commercially available

TORQUE:128 N*m (13.1 kgf*m, 94 lbf*ft)

Be careful not to damage the mainshaft threads.

Stake the lock nut [1] into the mainshaft groove with a punch.

Install the spring seat [1] and judder spring [2] onto the clutch center as shown.

Coat the clutch discs and plates with clean engine oil.

NOTE:

• Clutch disc A [1]: Identification mark [2] on a tab
• Clutch discs [3]: No mark
• Clutch disc B [4]: Large I.D.

Install the clutch disc B into the clutch outer.

Stack the five clutch discs, six plates [5] and clutch disc A alternately.

Install the clutch disc A by aligning the tab with the shallow slots [6] of the clutch outer.

Install the lifter bearing [1] into the pressure plate.

Install the clutch lifter piece [2] into the lifter bearing.

Install the pressure plate [1].

Install the clutch springs [2] and spring bolts [3].

Tighten the bolts to the specified torque in a crisscross pattern in two to three steps.

TORQUE:12 N*m (1.2 kgf*m, 9 lbf*ft)

Apply molybdenum oil solution to the starter idle gear shaft [1] outer surface.

Install the starter idle gear [2] and shaft.

Install the wave washer [1] and thrust washer [2] onto the starter idle gear.

Install the right crankcase cover.

See also: