Clutch Release Fork: Service and Repair
Release Bearing and LeverREMOVAL
1. Remove the transmission assembly from vehicle body.
2. Remove the two clips from clutch release lever and remove the release bearing.
CAUTION: Be careful not to deform clips.
3. Remove the release lever seal.
4. Remove the release lever retainer spring from release lever pivot with a screwdriver by accessing it through clutch housing release lever hole. Then remove the release lever.
INSTALLATION
1. Before assembly, lubricate the following points with a coat of grease.
^ Contact surface of lever and pivot
^ Contact surface of lever and bearing
^ Transmission main shaft spline (Use grease containing molybdenum disulphide.)
^ Contact surface of lever and operating cylinder
2. While pushing the fork to pivot and twisting it to both sides, fit the retainer spring onto the constricted portion of pivot. Apply grease (SUNLIGHT 2: P/N 003602010 to the contact point of release lever and operating cylinder.
3. Confirm that the retainer spring is securely fitted by observing it through the main case hole.
4. Install the release bearing and fasten it with two clips.
5. Install the release lever seal.
6. Verify that the bearing moves smoothly with operating release fork.
7. Install the transmission assembly.
INSPECTION
RELEASE BEARING
NOTE: Since this bearing is grease sealed and is of a non lubrication type, do not wash with gasoline or any solvent when servicing the clutch.
1. Check the bearing for smooth movement by applying force in the radial direction.
Radial direction stroke: 1.6 mm (0.063 inch)
2. Check the bearing for smooth rotation by applying pressure in the thrust direction.
3. Check wear and damage of the bearing case surface contacting with lever.
RELEASE LEVER
1. Check the lever pivot portion and the point of contact with release bearing case for wear.