clutch replacement...

[Julian Solomensky]

Hello James,

Clutch replacement is relatively simple.  Assuming nothing is broken, all you need is a new clutch cover gasket, springs, and steel plates and friction plates.  Chances are your steel plates are fine, but why take the and have to wait on parts should you need them?

I replaced my clutch at 45Kmiles with all OEM parts (look up the parts fiche on ronayers.com for part #'s).  I should add, @ 45K, the clutch felt like it was slipping - especially when taking off, however when actually pulling it all apart and measuring, there was PLENTY of material left.  I could of easily gone 60-70K on it with my type of riding.

If you do lots of city riding and/or are abusive then life will be shorter.

The job itself is real simple.  Remove cover, remove clutch basket bolts, R&R the plates.  Installation is reverse.

The most time consuming part was cleaning the old gasket off the two mating surfaces.  A friend has an autoshop and knows how to use the wirewheel to do this without damaging the part.  For the engine portion, I used a razor blade.  No leaks even now.

Besure to torque the clutch basket bolts properly using a torque wrench.  They are easy to over tighten.

Here's some part numbers and prices (from may of 2002).

92049-1061 SEAL-OIL 5.63 X QTY 1 = $5.63
13088-1107 PLATE-FRICTION 8.71 X QTY 9 = $78.39
13089-1092 PLATE-CLUTCH 5.30 X QTY 8 = $42.40
13144-1290 SPROCKET-OUTPUT 21.70 X QTY 1 = $21.70
49054-1051 THERMOSTAT 19.06 X QTY 1 = $19.06
92033-1040 RING, SNAP,43.5 1.74 X QTY 1 = $1.74
92033-1041 CIRCLIP,42MM 1.74 X QTY 1 = $1.74
120S0625 BOLT,SOCKET,6X2 1.04 X QTY 6 = $6.24
92033-1044 CIRCLIP,62M/M 3.49 X QTY 1 = $3.49
92200-1234 WASHER,TOOTHED, 1.28 X QTY 1 = $1.28
92049-1110 SEAL-OIL,AG1258 2.81 X QTY 1 = $2.81
92050-027 OIL SEAL 6.55 X QTY 1 = $6.55
92055-1470 RING-O 1.05 X QTY 1 = $1.05
92093-1383 SEAL 3.03 X QTY 1 = $3.03
92116-1067 BEARING-ROLLER, 23.45 X QTY 1 = $23.45
92116-1069 BEARING-ROLLER 23.45 X QTY 1 = $23.45
92144-1473 SPRING,CLUTCH 2.35 X QTY 6 = $14.10
92033-1043 RING,SNAP,52 M/ 2.68 X QTY 1 = $2.68

Note, I also did the wheel bearings, chain and something else I can't remember.

Isn't the internet great :)

Monday, May 7, 2007, 4:56:50 PM, you wrote:

> Ok..thanks to GPZ list members very good advice on tires, chain, sprocket,
> the bike is almost perfect.  Now I guess I need to replace the clutch.
> Clutch take up is all the way at the end of the lever and I was able to get
> clutch slip with no lever pull at all today.

> What's the best place to get parts for clutch replacement and how hard of a
> job is it?

> Thanks a million,
> James




-- 
Best regards,
 Julian                            mailto:jsolo at solo-tek.com