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History (18 Jul 2018)

Looking for any OB photos/videos/links that people may have if you have some to share can send me a PM and I will give u email address to send to. Thx C

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Fitting a new Clutch

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8 years 7 months ago #75699 by mal5.1
Replied by mal5.1 on topic Fitting a new Clutch
Nice work TB. Good easy to understand instructions.

Get rid of those digital verniers mate, they are crap. They issue them to builders cause that about how accurate they are. :P

Yamaha, Sherco, Husky, Gas Gas, Sherco…….what next?

Your brain and muscles fade very quickly without oxygen so remember to BREATH when riding.

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8 years 7 months ago #75700 by white rocket
Replied by white rocket on topic Fitting a new Clutch
good to see you fixed his clutch TB it was sliping on the orange to hillend ride when i rode his bike should go heaps better now

to old to fat to slow but still out there and talking shit

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8 years 5 months ago #80709 by Roundeyedevil
Replied by Roundeyedevil on topic Fitting a new Clutch
Trailboss wrote:

So some of you maybe following the thread regarding Crash's up and coming condo 750 ride and it was mentioned that once the bike was sorted and rubber fitted it was found the clutch was slipping. All the normal things checked out, clutch had free play at the arm etc. Crash with no time to muck around ordered new friction plates, steel plates and pressure springs.

This morning I grabbed his bike on the trailer over to my place. I already had the clutch parts as I picked them up the day before, the friction plates I had soaking in engine oil ready to go.

Firstly threw the bike on its side (bike had no problem with that spends a fair bit of ride time there :laugh: )



By doing this I dont need to drain the gearbox / engine oil and prevents any dripping mess

Undo the 7 Bolts around clutch cover, thankfully Honda run a rubber "o" ring so its reusable



Cover off, now undo the 4 bolts that retain and the springs that clamp the clutch plates to provide drive, when you pull the clutch in you pull against the springs unclamping the plates



Weak springs here reduce the pressure the plates are clamped together with which can cause the clutch to slip, to stiff a springs makes the clutch harder to pull in need a balance

Pressure off the springs and 3 of the bolts removed



Now to measure the springs and compare them against the new ones

Old 47.30mm



New 48.57mm



So about 1.2 mm difference and well within spec of 45.40mm

I then pulled the clutch pack out 1 plate and steel spacer plate at a time to inspect them all and keep them in order for easy reassembly. First thing I noticed was how burnt the clutch facing material was and the steel spacer plates had been blued. Crash does use a fair bit of clutch slipping you have to on a XR650 in some of the tight going, also on his last wet ride the clutch may have been slipping a bit and being wet he may not have noticed. When the clutch slips it generates huge amounts of heat, thus the bluing you see in the photos



Once into a nice stack and sorted there are no other dramas the clutch baskets fingers are inspected these are ok



The plates soaking in oil waiting assembly



I used some of the quailty Muc-Off disc brake cleaner to clean the packaging goo of the steel plates

Reassembling via the old stack if in doubt, steel plate



Last fibre plate



Pressure plate bolted back on with new springs



Finished



For this job I used a "Y" brace 8mm, 10mm and 12mm. 1/2 litre of engine oil, clean tin to soak the plates, a rag and the Muc-off disc cleaner. The verniers you could do without.
The job took 15mins including taking the photos and is very simple. If in doubt lay it out go step by step

The test ride confirmed the repair, third and fourth gear wheelies Crash no slip ;)

Now to write the invoice and the job is done


TB

Thanks TB for this write up I ordered a new EBC kit with springs and all the plates on ebay and did it today .At first I was a little worried but it all turned out well once I did my test ride.I have a brand new Metzler as well so the ol XR is ready for some work

My bikes of choice XR400,NX650 & my sons CRF 50

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8 years 5 months ago #80755 by TB
Replied by TB on topic Fitting a new Clutch
Hey glad it helped XRtrailhack, I love the real DIY stories from contributors here and thought I would do one myself. We did a good tyre change video with explanations at the Kenda I will post up. Also we are having a tyre change and tech night at Sutto's on a thursday soon where tyre changing and other trail side tips will be discussed and hands on learning will be supervised by Sutto and some of the other experienced guys there. Pizza and refreshments as well :laugh:


TB

In the end, it's not going to matter how many breaths you took, but how many moments took your breath away

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7 years 4 weeks ago #113839 by TB
Replied by TB on topic Fitting a new Clutch

Burkey wrote: OK this thread is older than my undies, is there a consent on the best replacement clutch to use. Mine only has about 4600 k's on her (02 model) owned it for about 15 months and have a small/occassional amount of slippage

Whats the preference ??


Hi Burkey, the kit above I fitted to Crashes bike was just a basic kit he got local. Two thoughts here from me, my clutch is 45k old its done A4DEs, trail rides, Condos, Yellow Mountains etc and still doesnt slip and I fan the shit out of it. The clutch in mine is a Nick Doyle Tekinks special which has CR250 plates and no judder spring plate I am told, if you are interested ring 02 47322622 and speak with Nick. I cant recommend that setup enough. My other thought would be a Barnett clutch kit, they are tough unbreakable and good value for money.
Hope some of the above helps

TB

In the end, it's not going to matter how many breaths you took, but how many moments took your breath away
The following user(s) said Thank You: Burkey

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