Yamaha pw80 - Manual (Page 39)

1. Rotor Holder
4. Remove the circlip, pressure plate, clutch
plates, friction plates, one-way clutch,
and clutch boss from the clutch housing.
Inspection
1. Measure each clutch spring and off
spring. If beyond tolerance, replace.
^ New Minimum
OFF spring free length
30.5 mm
(1.20 In)
28.5 mm
(1.12 in)
Clutch spring free length
12.9 mm
(0.51 in)
11.9 mm
(0.47 in)
NOTE: ------------------------------------------
For optimum performance, if any plate requires
replacement, it is advisable to replace the en­
tire set.
4. Check each clutch plate for signs of heat
damage and warpage. Place on surface
plate (plate glass is acceptable) and use
feeler gauge.
Clutch plate warp allowance:
0.1 mm (0.004 in)
5. Checking the ball
Check balls for excessive wear or damage.
If such wear is found, replace balls.
Checking the ratchet mechanism
Check for damage or wear on each pawl
and dog. If damaged or worn to excess,
replace it. Check the pawl-spring for
damage and tension. If damaged or
fatigued to excess, replace it.
2. Check the plates for signs of warpage and
heat damage, replace as required.
3. Measure the friction plates at three or four
points. If their minimum thickness ex­
ceeds tolerance, replace.
New Wear limit
Friction plate
thickness
3.0 mm
(0.118 In)
2.7 mm
(0.106 in)
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