2004-2009 Honda TRX450R/TRX450ER Service Manual, Page 265Get this manual
CLUTCHSTARTER CLUTCHKICK STARTERGEARSHIFT LINKAGE (After '05)
SERVICE INFORMATION
GENERAL
This section covers service of the clutch, starter clutch, kickstarter and gearshift linkageThese services can be performed with the engine installed in the frame Transmission oil viscosity and level and the use of oil additives have an effect on clutch disengagementOil additives of any kind are specifically not recommendedWhen the clutch does not disengage or the vehicle creeps with the clutch disengaged, inspect the transmission oil viscosity and level before servicing the clutch system
SPECIFICATIONS
ITEM Clutch Lever free play Spring free length Disc thickness Disc thickness Plate warpage Driven gear boss (TRX450ER) Reduction gear I.D(TRX450ER) Reduction gear I.D(TRX450ER) Idle gear I.D(TRX450ER) Gear holder shafts O.D(TRX450ER) Reduction gear shaft O.D(TRX450ER) Kickstarter Pinion gear I.D(TRX450R) Spindle O.DIdle gear I.DIdle gear bushing STANDARD 10-20(38-34) 45.7(1.80) 2.92-3.08(0.115-0.121) 3.22-3.38(0.127-0.133) 36.00936.034 (1.41771.4189) 45.66045.673 (1.79761.7981) 12.01012.050 (0.47280.4744) 10.04510.085 (0.39550.3970) 12.01012.050 (0.47280.4744) 11.98912.000 (0.47200.4724) 9.9809.995 (0.39290.3935) 22.00722.028 (0.86640.8672) 21.95921.980 (0.86450.8654) 21.020-21.041 (0.8276-0.8284) 17.00017.018 (0.66930.6700) 20.97921.000 (0.82590.8268) 16.96616.984 (0.66800.6687) Unit: mm (in) SERVICE LIMIT 44.7 (1.76) 2.85(0.112) 3.15(0.124) 0.15 (0.006) 36.034(1.4189) 45.660 (1.7976) 12.050(0.4744) 10.085 (0.3970) 12.050(0.4744) 11.989 (0.4720) 9.980 (0.3929) 22.05 (0.868) 21.95 (0.864) 21.07 (0.830) 17.04(0.671) 20.96 (0.825) 16.95(0.667)