clutch repair

petbro1 · Jun 30, 2008

hello chaps, not been here for a while, bought a nice old 501, 1993 or 94. not sure. but the clutch is slipping alot once past 2nd open her up and it slips, i have ordered the new friction plates but have never done a clutch before. i have the manual from here so can follow that to a degree, but just wondered if there's any special tips i should know, and is it a fairly easy job, it don't seem to complicated to me YET

oyk · Jul 1, 2008

just lay the bike down from the right side,this way you can avoid oil on the floor.

remove shift lever and kickstart.

remove clutch cover.
be carefull not to loose the 2 guides of the cover

be carefull not to move the kickstart gear
check also the oring on to the kickstart shaft

use a 10mm socket wrench to remove the pressure plate screws.

if their washers are aluminium check for cracks.

remove pressure plate and check its bearing for wear.

remember that the small thin washer's position is right between the bearing and the push rod, it is critical because otherwise you might damage rotating actuator.

while you are there check the reed valve.

check the clutch basket for wear especially the bushing

remove the plates and replace with new ones following the same order.

tighten the screws back to aproximatelly 12nm

put back together everything.

i thing you should be ok

petbro1 · Jul 2, 2008

many thanx sounds a peice of piss 8)

petbro1 · Jul 3, 2008

problem, i fitted the new plates and done it all back up as per manual, was very careful in removing everything and took a mental note and marked everything. but i now have no clutch at the lever, it seems the arm at the end of the cable is not moving the pushrod enough, ive played around trying to get it to locate better but it wont. please help i need it for the weekend

petbro1 · Jul 3, 2008

come on guys i'm desperate :crying:

oyk · Jul 4, 2008

mental note??

not enough apparently

now when you open it again take pictures WHEN YOU PUT THE THIN SPACER BETWEEN THE PUSHROD AND THE BEARING IN THE RIGHT POSITION LIKE I TOLD YOU

petbro1 · Jul 5, 2008

ok i sorted it out now cheers

clutch repair

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