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7/21/2009
Location
Harrisburg, OR
US
Edited Date/Time
1/9/2013 7:33pm
I didn't have an impact wrench so I threw in the towel pretty quickly, I think my buddy is gonna bring his down today before we watch A1. Anything in particular I should know about getting the flywheel nut off and the clutch basket it out? (that's the part I'm attempting to replace) What about things I should look for once the basket is out of the way, like wear and tear on other internals? Any help would be great, thanks.
Be careful with the flywheel nut, don't use an impact socket on the gun. Use a regular socket, the nut isn't on there that tight anyway. Or shouldn't be. I say this because an impact socket will possibly trash the threads on your flywheel, then the war is on trying to get your puller in. You do have the proper puller, correct?
Be careful with the lock tab washer when bending the tang back down, you'll likely be re-using it. Not necessary to have a brand new one, but it is nice. Just look at at the washers in the clutch assembly for wear, but typically those don't go to shit. Are you installing a Hinson or Barnett basket? Because your OEM is grooved up?
Go REAL light with the impact on the mainshaft nut re-install, if that's the route you're going. Good luck.
The Shop
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You're in Eugene, not far from MotoSport Outlet, in Portland. (Forgive me if I forget how far it is, it's been 10 years since I made that drive.) Drive up and buy a puller for 20 bucks, or mail order it in. Save your money on gas. Order in a main clutch cover gasket as well, in case your old one is trashed. Most likely it will be when you're done. Get a manual as well, don't work in the blind, and don't guess.
To pull the basket, I'm sure you have to yank the full clutch side cover, not just the one you show in the photo.
35 years ago, I didn't know much either, we all have to start learning from somewhere and someONE else.
What you are trying to remove is sometimes referred to as the "Clutch Hub" or "Clutch Inner Hub"
After you get the hub nut off you shouldn't need a puller. It should slide right off.
To remove it after getting the right side case cover off (if needed)....
- Flatten lock washer
- Install clutch plates (fibers/steel)
- Put pressure on the outer fiber plate and remove nut with impact gun
To swap the basket gear over (last time I did one) you will need a grinder of some sort to remove the rivet heads.
If you don't have a grinder and an impact gun don't bother going any further cause you will just get stuck again.
Let us know how it turns out....
Like scooter said, get the manual, and do not be afraid to try things. You will have a few screw ups, but it happens.
Just try and be as careful / observant as you can. Take your time.
You can make a simple, cheap clutch hub holder out of a piece of round bar, an old steel clutch plate, and a minute of welding. And a strap type oil filter wrench will usually hold the flywheel enough to get the nut torqued to spec.
When pulling the clutch basket off, take the bolts and springs out of the pressure plate and remove the plate. Leave the clutch plates in for now as the will help hold the whole assembly from spinning when you hit the nut with the impact gun. I'm sure you are not going to have the right clutch holder so in a pinch, just hold the assembly with a rag but be careful! The nut should come off easily.
One the flywheel side, once you have the bolt and washer off, make sure the threads on the inside of the flywheel are spotlessly clean. They are very fine and can be damaged very easily. Back the center bolt out of the puller out so it wont contact the crankshaft when the puller is threaded in. Thread the puller all the way into the flywheel but don't tighten it at all, just until it stops. Now spin the center bolt in until it contacts the crank but again, don't tighten it. Now hold both the center bolt and the outer puller and back the puller out 2 or 3 turns. Now spin the center bolt back in until it contacts the crankshaft and SNUG it with the appropriate wrench, usually an Allen key. The idea here is to use the OUTER part of the puller to do the work. Now use the proper sized box end wrench to turn the outside part of the puller until you hear and feel a "pop". Your flywheel is now off.
I know it sounds complicated but it's not at all, and its critical that it be done this way, otherwise you risk damaging the flywheel and or the crankshaft.
The steel plates are machine stamped out of sheet steel therefor they have a rounded side and a flat side. It is very important to install ALL the the steel plates with the rounded sides facing the same way. All of them facing in, or all of them facing out it dosen't matter, as long as all of the are the same way.
Pit Row
:facepalm:
Hope you get it fixed.
I would also recommend putting some new clutch springs in while you have it apart, order a replacement set and change them again in 3-6 months.
I don't see how the gear jammer will prevent the clutch hub from spinning.
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