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 the clips.
3. Remove the dust cover.
4. Remove the lever spring from 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 disulphide.)
1. While pushing the release lever to pivot and twisting it to both sides, fit the lever spring onto the constricted portion of pivot.
NOTE:
^ Apply grease (SUNLIGHT 2: Part No. 003602010) to the contact point of release lever and operating cylinder.
^ Observing from main case hole, check that the lever spring is installed securely.
2. Place the release bearing and fasten it with two clips.
3. Install the dust cover.
4. Check the bearing for smooth movement of with operating release lever.
5. Install the transmission assembly.
INSPECTION
RELEASE BEARING
NOTE: Since this bearing is grease-sealed and 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 to the bearing in radial direction.
Radial direction stroke: 1.6 mm (0.063 inch)
2. Check the bearing for smooth rotation by applying force to the bearing in thrust direction.
3. Check wear and damage of bearing case surface contacting with lever.
RELEASE LEVER
Check the lever pivot portion and contact point with release bearing case for wear.