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Pinion Assembly/Clutch Armature/Clamp
310893L 11
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.
FIG. 8
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
6. F
IG. 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. F
IG. 4. Install pinion assembly (29) with four screws (36)
and washers (37).
12. F
IG. 14. Connect clutch cable connectors to inside of
pressure control.
Clamp Removal
1. Do Engine Removal.
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.
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)
Face of clutch housing
1.550 ± .010 in. (39.37 ± .25 mm) - GMAX 3900
2.612 ± .010 in. (66.34 ± .25 mm) - GMAX 5900 & 7900
Torque to 125 ±.10 in-lb (14 ±1.1 N·m)
Chamfer this side
FIG. 10
0.12+01 in (3.0+.25 mm)
25
26
dimes
ti6321a
WARNING
Gasoline can spill and cause a fire or explosion if
engine is tipped on side.
ti6199a
1
2
33
44
"
!
TIA
19