CLUTCH. Honda CBR125R

Install the right crankcase cover, clamp and bolts.

Tighten the bolts in a crisscross pattern in 2 or 3 steps.

CLUTCH/GEARSHIFT LINKAGE

BOLTS

Connect the water hoses and tighten the water hose

band screws (page 6-14).

BOLT/CLAMP

WATER HOSE

Connect the clutch cable.

Adjust the clutch lever freeplay (page 3-24).

Fill the engine with the recommended engine oil

(page 3-13).

Fill the recommended coolant mixture to the filler

neck and bleed the air (page 6-6).

BAND SCREWS

CLUTCH CABLE

CLUTCH

REMOVAL

Remove the right crankcase cover (page 10-5).

Remove the clutch lifter bearing.

Remove the clutch spring bolts in a crisscross pattern in 2 or 3 steps.

Remove the clutch lifter plate and clutch springs.

BEARING BOLTS/SPRINGS

PLATE

10-9

CLUTCH/GEARSHIFT LINKAGE

Install the clutch center holder and tighten the clutch spring bolts securely.

Loosen the clutch center lock nut using the special tools.

TOOLS:

Clutch center holder

Lock nut wrench, 20 x 24 mm

Extension bar/handle

07GMB-KT70101

07716-0020100

07716-0020500

CLUTCH CENTER HOLDER LOCK NUT

LOCK NUT WRENCH

Remove the clutch center lock nut and washer.

LOCK NUT

Remove the following:

– Clutch center

– Clutch disc

– Clutch plates

– Pressure plate

Remove the clutch outer.

CLUTCH CENTER

PLATES

WASHER

CLUTCH OUTER

DISCS

PRESSURE PLATE

10-10

CLUTCH/GEARSHIFT LINKAGE

Remove the clutch outer guide and washer from the mainshaft.

CLUTCH OUTER GUIDE WASHER

INSPECTION

CLUTCH LIFTER BEARING

Turn the inner race of the lifter plate bearing with your finger.

The bearing should turn smoothly and quietly.

Also check that the bearing outer race fits tightly in the lifter plate.

Replace the bearing if the inner race does not turn smoothly, quietly, or if the outer race fits loosely in the lifter plate.

Replace the clutch springs as a set.

CLUTCH SPRING

Check the clutch spring for fatigue or damage.

Measure the free length of the clutch spring.

SERVICE LIMIT: 38.3 mm (1.51 in)

CLUTCH CENTER

Check the grooves of the clutch center for nicks, indentations or abnormal wear made by the clutch plates.

BEARING

CLUTCH CENTER

GROOVE

10-11

CLUTCH/GEARSHIFT LINKAGE

Replace the clutch discs and plates as a set.

CLUTCH DISC

Replace the clutch discs if they show signs of scoring or discoloration.

Measure the disc thickness of each disc.

SERVICE LIMIT: 2.65 mm (0.104 in)

CLUTCH DISC

Replace the clutch discs and plates as a set.

CLUTCH PLATE

Check the plate for discoloration.

Check the clutch plate for warpage on a surface plate using a feeler gauge.

SERVICE LIMIT: 0.20 mm (0.008 in)

Warped clutch plates prevent the clutch from disengaging properly.

CLUTCH PLATE

CLUTCH OUTER/OUTER GUIDE

Check the slots of the clutch outer for nicks, cuts or indentations made by the clutch discs.

Check the primary driven gear teeth for wear or damage.

Measure the clutch outer I.D.

SERVICE LIMIT: 30.54 mm (1.202 in)

Measure the clutch outer guide I.D. and O.D.

SERVICE LIMITS:

I.D.: 17.04 mm (0.671 in)

O.D.: 22.93 mm (0.903 in)

CLUTCH OUTER

MAINSHAFT

Measure the mainshaft O.D. at the clutch outer guide.

SERVICE LIMIT: 16.59 mm (0.653 in)

OUTER GUIDE

MAINSHAFT

10-12

INSTALLATION

LIFTER PLATE

BEARING

12 N·m (1.2 kgf·m, 0.9 lbf·ft)

CLUTCH/GEARSHIFT LINKAGE

CLUTCH SPRING

CLUTCH PLATE

(four pieces) CLUTCH DISC

(five pieces)

WASHER

74 N·m (7.5 kgf·m, 55 lbf·ft)

WASHER

CLUTCH CENTER

CLUTCH OUTER GUIDE

CLUTCH OUTER

PRESSURE PLATE

Install the washer to the mainshaft.

Apply molybdenum oil solution to the clutch outer guide outer surface and install it to the mainshaft.

CLUTCH OUTER GUIDE WASHER

Install the clutch outer.

CLUTCH OUTER

10-13

CLUTCH/GEARSHIFT LINKAGE

Apply engine oil to the clutch disc entire surfaces.

DISCS/PLATES

Assemble clutch discs, clutch plates and pressure plate onto clutch center, while aligning " " mark of clutch center and pressure plate.

CLUTCH CENTER PRESSURE PLATE

Install the tabs of the clutch disc (out side) into the shallow slots in the clutch outer.

Install the clutch center assembly into the clutch outer.

CLUTCH OUTER

Align

SHALLOW SLOT

Install the washer.

Apply engine oil to the clutch center lock nut threads and seating surface and install it.

CLUTCH CENTER ASSEMBLY

LOCK NUT

WASHER

10-14