Important

If starter clutch, clutch shell or clutch gear have been replaced, it is absolutely necessary to check the clearance between teeth on starter clutch gear and starter clutch as described in "Starter," Section 4C.

Tighten and adjust front chain tensioner as described under "Front Chain Adjustment," Section 2B.

See Fig, 4B-8. Remove locking tools and install backing plate (13) over clutch hub splines, against back side of hub, recessed side facing out.

Place a steel plate (12) next to the recessed plate (13). Place a friction plate (11) into clutch shell and sprocket assembly and push inward against the second metal plate. Alternate with steel plates and friction plates until seven friction plates are in position. This will leave a friction plate on the outside. Make sure all plates have free movement.

Install releasing plate (10) on clutch hub (16) so the clutch hub studs are exactly centered in the clutch spring cup holes. Do this by aligning the larger of the two depressions on the rim of the clutch releasing plate with the notched tooth of the clutch hub.

Install clutch spring cups (9), springs (8) and springtension adjusting plate (7) into position with the raised surface facing outward. Start three 1/2 in. hex-head (long) nuts (6) on their respective studs. Pull these nuts down evenly until the spring-tension adjusting plate is pulled over the remaining three studs a sufficient distance to allow starting the 7/16 in. hex-head nuts (5). Draw the six spring-tension adjusting nuts down evenly until the inside of the spring-tension adjusting plate (7) measures 3/16 in. out from the outside surface of flange of the clutch spring cups (9) at the 6 stud locations. This is proper clutch spring-tension adjustment when new clutch plates are used. Install clutch shell and sprocket cover (3), screws (1) and retainers (2), with new gasket (4). Install gasket without sealer, graphite-side facing cover. Very lightly stake retainer (2) to lock screw (1).

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A heavy blow is very likely to distort cover, disjoining the seal.

1. Sprocket shaft nut

2. Sprocket spring

3. Sprocket sliding cam sleeve

4. Sprocket sliding cam

5. Engine sprocket

6. Sprocket shaft extension

Figure 4B-12. Compensating Sprocket - Exploded View

See Fig. 4B-7. Install chain cover (5) and screws (4) with new gasket. If necessary, use gasket seal on both sides of gasket. Assemble rear brake pedal (3), stoplight switch (2) and footrest (1).

With motorcycle standing straight up, remove oil filler plug (6) and oil level plug (7). Add oil through filler plug, (same grade of oil used in engine), until it begins to overflow through oil level hole. Allow excess oil to flow from hole (7) until it ceases to run. This is correct oil level. Reassemble oil level and and filler plugs.

REMOVING COMPENSATING SPROCKET (Fig. 4B-12)

Loosen clutch sprocket and front chain as described in "Disassembling Clutch." Then remove compensating sprocket shaft nut (1), using Shaft Nut Wrench, Part No. 94557-55, as shown in Fig. 4B-10. Remove spring (2), sliding cam sleeve (3), sliding cam (4), sprocket (5), front chain and clutch shell together. Use Sprocket Shaft Extension Puller, Part No. 9601556, to remove extension (6) from sprocket shaft if necessary (see Fig. 4B-13).

INSPECTING COMPENSATING SPROCKET (Fig. 4B-

Wash all parts in cleaning solvent and blow dry with compressed air. Carefully examine sprocket teeth, shaft splines and sliding cam surfaces for wear or scoring. Replace any parts that show excessive wear or damage.

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