Honda CBR 954RR Service Manual 09 clutch

CLUTCH/GEARSHiFT LINKAGE

12

N-m

(1

.;

kgf-m, 9 Ibf-ft)

12

N-m (1.2'kgf-m, 9 Ibf-ft)

9.

1

SERVICE INFORMATION

CLUTCH/GEARSHIFT

9-1

CLUTCH

LIN

9-4

E

~

TROUBLESHOOTING
RIGHT CRANKCASE COVER

REMOVAL

S E RVI

CE I N

FORM

ATI

0

N

9-2

9-3

GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER

INSTALLATION

9-12

9-17

GENERAL

-

This section covers service of the clutch, gearshift linkage, shift drum and shift forks.
engine installed in the frame.
Engine oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motor

cycle creeps with clutch disengaged, inspect the engine oil level before servicing the clutch system.

Clutch lever free play
Clutch spring free length
Clutch disc thickness
Clutch plate
Clutch outer guide

1

Mainshaft

1

Shift fork, fork 1 Fork

warpage

O.D.

at clutch outer quide

Fork shaft

ITEM

O.D.

I

1

I.D.

O.D.

I.D.

Claw

~

thickness

10 - 20 (318 - 13/16)

48.8 (1.92)

2.92 - 3.08 (0.114 - 0.121)

1

25.000 - 25.021 (0.9843 - 0.9851)

~

34.975 - 34.991 (1.3770 - 1.3776)

24.980 - 24.993 (0.9835 - 0.9840)

~

1

12.000 - 12.018 (0.4724 - 0.4731)

5.93

-

6.00

11.957

-

11,968 (0.4707 - 0.4712)

STANDARD

-

(0.233 - 0.236)

All service can be done with the

SERVICE

LIMIT

-

47.4 (1.87)

,

2.6 (0.10)

1

0.30 (0.012)

1

25.03 (0.985)

'

34.97 (1.377)

1

24.96 (0.983)

1

12.03 (0.474)

(0.23)

5.9

11.95 (0.470)

-

I

1

TORQUE

Clutch center lock nut
Clutch spring bolt

Shift drum center socket bolt
Shift drum stopper arm pivot bolt
Gearshift return spring pin
Gearshift drum
retaining bolt
Gearshift pedal link pinch bolt
Oil pump driven sprocket bolt

VALUES

bearingkhift fork

shaft

127

N*m (13.0 kgf-m, 94 Ibf-ft)

12 N.m (1.2 kgf-m, 9 Ibf-ft)

23 N*m (2.3 kgf-m, 17 Ibf-ft)

12 N*m (1.2 kgf-m, 9 Ibf-ft)

23 N-m (2.3 kgf-m, 17 Ibf-ft)

N*m (1.2 kgf-m, 9 IbfW

12

10 N-m (1.0 kgf-m, 7 IbfW

15 N-m (1.5 kgf-m, 11 Ibf-ft)

Apply oil to the threads.
Stake the nut.

Apply a locking agent to the threads.

Apply a locking agent to the threads.
Apply a locking agent to the threads.

CLUTCH/GEARSHIFT LINKAGE

TOOLS

Clutch center holder 07724-0050002 or equivalent commercially available in

Driver 07749-0010000

07746

-

Attachment, 42
Pilot,

35

mm

x

47 mm

0010300

07746-0040800

TROUBLESHOOTING

Clutch lever too hard

Damaged clutch lifter mechanism
Faulty clutch lifter bearing

Clutch lifter piece installed improperly

Clutch slips when accelerating

Worn clutch disc
Weak clutch springs

*

Transmission oil mixed with molybdenum or graphite addi

tive

Clutch will not disengage or motorcycle creeps with clutch

disengaged

Clutch plate warped
Loose clutch lock nut
Oil level too high
Improper oil viscosity
Damaged clutch lifter mechanism
Clutch lifter piece installed improperly

to

pull in

Transmission jumps out

Worn shift drum stopper arm
Weak or broken shift arm return spring

Loose stopper plate bolt
Bent shift fork shaft

Damaged shift drum cam groove
Damaged or bent shift forks
Worn gear engagement dogs or slots

-

Gearshift pedal

Weak or broken gearshift spindle return spring
Bent gearshift spindle

will

of

gear

not return

U.S.A.

Hard

to

shift

Improper clutch operation
Improper oil viscosity
Bent shift fork
Bent shift fork shaft
Bent fork claw
Damaged shift drum cam groove
Loose stopper plate bolt
Damaged stopper plate and pin
Damaged gearshift spindle

9-2

RIGHT CRANKCASE

COVER

REMOVAL

CLUTCH/GEARSHIFT

2P

(RED)

CONNECTOR

LINKAGE

Drain the engine
Remove the lower cowl (page
Open and support the front end of the fuel tank (page

3-4).

Disconnect the ignition pulse generator
nector.

Remove the bolts and clutch cable bracket, then dis
connect the clutch cable end from the clutch lifter
lever.

oil

(page

3-15).

2-7).

2P

(Red ) con

-

-

The

iifterarm

spindie

engaged

c’utch

inside

crankcase

wit

the

Ihe

piece

right

cover

Remove the right crankcase cover

is

Remove the right crankcase cover while turning the
clutch lifter arm counterclockwise
lifter arm spindle from the lifter piece.

Remove the two dowel pins.

Clean any sealant
mating surfaces.

off

from the right crankcase cover

SH

bolts.

to

disengage the

CLUTCH/GEARSHIFT

LINKAGE

Instail the

spring to the right

crankcase cover

and

hooks

of the return

clutch lifter

lever.

CLUTCH

Remove the clutch lifter lever, return spring and wash
er from the right crankcase cover.

Check the lifter lever spindle for wear or damage.

Check the return spring for fatigue or damage.

Check the lifter lever oil seal and needle bearings for
wear or damage.
Install the clutch lifter lever with the washer and
spring in the reverse order of removal.

LIFTER

LEVER

-

WASHER

LIFTER

LEVER

CLUTCH

REMOVAL

Remove the right crankcase cover (page
Remove the clutch spring bolts, springs and pressure

plate.
Remove the clutch lifter piece from the lifter bearing.

Remove the following:

-

Nine clutch discs

-

Eight clutch plates

-

Judder spring

-

Judder spring seat

9-3).

Oli

SEAL

Unstake the clutch center lock nut.

Hold the clutch center with the clutch center holder,

then remove the lock nut.

TOOL:

Clutch center holder

07724-0050002
(Equivalent commer
cially available in

U.S.A.)

CLUTCH/GEARSHIFT

-

LINKAGE

Discard the lock nut.

Remove the lock washer, thrust washer and clutch

center.

Remove the washer.

9-5