anatomy of a clutch basket replacement
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Anatomy of a Clutch Basket Replacement. Daniel M. O\'Brien, (c) 2003 . Converted to PowerPoint by Janice Clanfield, 2008. Put the bike on center stand, not absolutely necessary, but helpful for draining fluids . This is the clutch side of the engine case, where the glass oil sight is.

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anatomy of a clutch basket replacement

Anatomy of a Clutch Basket Replacement

Daniel M. O\'Brien, (c) 2003

Converted to PowerPoint by Janice Clanfield, 2008

slide6

Remove the nose piece, and right side fairing, the engine guards keep the fairing from coming off easily, so I had to remove the black piece from the fairing first

and leave the black piece in place no need to remove it note the radiator cap don t remove it yet
And leave the black piece in place, no need to remove it, note the radiator cap, don\'t remove it yet!
slide10

Remove the lower coolant drain hole, it will drip just a little, put a container under it, remove the radiator cap, and watch out as it comes out fast! there\'s another drain hold to the right, follow manual

slide11

Remove the radiator hoses from the water pump, a 1/4" hand driver works well with a 6mm socket, two hoses need it, other is simple squeeze clamp, note the pan below to catch incidental coolant and oil (don\'t tell my spouse, but its her turkey pan)

slide12
Water pump housing showing the three connections with hoses removed (I don\'t know why, but this picture is one of my favorite)
slide16

Remove the water pump housing (remove all the housing perimeter bolts), leaving the "O" ring (not really an O is it?), note the impeller, you will have to turn this to get the impeller shaft into its gear when installing the clutch cover

slide17

Then remove the clutch cover housing by removing all the perimeter bolts first, then it just pulls off, there will be some extra drainage, thus the pan

slide18

Next, again with hex bit socket, remove the clutch pressure plate springs, loosen all first, then remove opposite bolts, when down to last two loosen both equally until they come out, remove top pressure plate

slide19

The pressure plate removed, leaves the clutch plates, also remove the clutch rod, bearings and washer are likely stuck to the inside of the top pressure plate

slide20

Remove the clutch plates (drive and driven), in order, and put them on the pressure plate, note the clutch rod, bearings, and washer

slide21

All that is left is the inner hub that drives the transmission and the clutch basket that is driven by the engine, note the big nut in the center (30mm or 1 3/16")

slide26

The bearings the basket rides on (it will slip forward when you pull the clutch basket off), and below is the oil pump gear driven by the clutch basket (make note of this gear, you must align the gear when putting the new clutch basket on!)

slide27

Note the brass screen trapping major metal filings so they don\'t flow thru the system, below the oil pump gear

slide28

The oil pump drive gear is removed from the clutch basket with a ring pliers (see the inner hub next to it)

slide29

Removing the ring, gear and a type of keyway that engages the oil pump gear with the clutch basket, these are reused in the new basket

slide30

As you go along, keep all related fasteners together in bags, fairing and body parts, clutch cover, and clutch pressure springs

slide31

For the installation section, the most important tool is the Service Manual -- don\'t proceed without it! Torque Specs are in the back if not in the specific procedures (clutch cover, foot peg)

slide32

Here are all the parts that we are replacing, clutch basket (comes with new hub sleeve), clutch cover gasket, water pump O ring, clutch hub nut and convex washer. Here\'s my order, all of these should be replaced together.21200-06811 GEAR ASSY,PRIMA = $182.4809164-24006 WASHER CL SLEEV = $1.4811482-06G00 GASKET,CLUTCH C = $6.5117435-02F00 O-RING,WATER PU = $4.3609159-24010 NUT = $5.25Subtotal: $200.08Shipping: $15.00Grand Total: $215.08

slide34

I was suprised to find the clutch hub sleeve with the new basket, not sure why they are replaced as a unit since there is a bearing set that is reused

slide35

"There she is, Miss America..." or is that Miss Universe, anyway, she\'s exposing herself a bit, but don\'t worry, the doctor will soon take care of this

slide40

Wiggle the oil pump drive gear so that it also engages, so you can

slide the clutch basket all the way back

slide42

Slip on the flat washer and the NEW convex washer,

note the orientation of the convex washer

slide47

Put the drive and driven plates back in the order they came out, if you\'ve mixed them up, then you need to review the manual and take measurements to determine which kind of plate goes where

slide56

This slot will match the tab on water pump impellor, you may have to

turn the impeller to get the tab to line up with the slot on the gear

slide57

Put the clutch cover back on, aligning everything including the water pump impeller, should slip on all the way around by hand, ya, you can hit it with your fist, but it must fit flat before putting in the bolts

slide58

Put the "O" ring into the water pump housing cover, manual

says to apply a little grease to the O-ring

slide59

Sort out all the bolts and put them into the holes accordingly, hint: the three longest go into the water pump housing, torque it all down by slowly tightening opposite bolts a little at a time, torque to specifications, go slow!

slide64

Follow service manual procedures for clearing air in the coolant system, keep topping off. Several starts, bike on side stand, heat/cool cycles, etc, to clear the air. May still suck coolant out of the overflow tank next few days

slide65

While engine is running, heating, put on chin guard (the "big-o" screw driver handle was used to tap the thermostat housing on the opposite side while the engine was running to dislodge any air bubbles)

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