Clutch Release Fork: Service and Repair
Release Bearing and LeverREMOVAL
1. Remove the transmission assembly from vehicle body.
2. Remove the two clips from the clutch release lever and remove the release bearing.
CAUTION: Be careful not to deform the clips.
3. Remove the dust cover.
4. Remove the lever spring from the pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever.
INSTALLATION
NOTE: Before or during installation, lubricate the following points with a light coat of grease.
^ Contact surface of lever and pivot
^ Contact surface of lever and bearing
^ Transmission main shaft spline (Use grease containing molybdenum disulfide.)
1. While pushing the release lever to the pivot and twisting it to both sides, fit the lever spring onto the raised portion of the pivot.
NOTE:
^ Apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of the release lever and operating cylinder.
^ Observing from the main case hole, check that the lever spring is installed securely.
2. Install the release bearing and fasten it with two clips.
3. Install the dust cover.
4. Check the bearing for smooth movement by operating the release lever.
5. Install the transmission assembly.
INSPECTION
1. RELEASE BEARING
NOTE: Since this bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or any other solvent when servicing the clutch.
1. Check the bearing for smooth movement by applying force to the bearing in the radial direction.
Radial direction stroke: 1.6 mm (0.063 inch)
2. While applying force to the bearing in the rotational direction, check the bearing for smooth rotation.
3. Check for wear and damage at the bearing case surface in contact with the lever.
2. RELEASE LEVER
Check the pivot portion of the lever and the contact area with the release bearing case for wear.
