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

Drain the oil while hot, the chin guard will be

removed after draining the oil

A set of hex bits sockets really help a lot

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!

Here are our body parts removed, fairing, chin guard, and nose piece

Next we drain the coolant

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

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)

Water pump housing showing the three connections with hoses

removed (I don't know why, but this picture is one of my favorite)

Need to remove right hand footpeg, again, hex bit sockets

are the best

Peg and brake pedal come off as unit, twist out of the way

The brakelight switch spring comes off the brake pedal and just moves up out of the way

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

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

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

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

Remove the clutch plates (drive and driven), in order, and put them on the pressure

plate, note the clutch rod, bearings, and washer

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")

This nut holds it all together, must relieve the detent with a hammer and chisel

Holding the hub with clutch hub tool, use socket and

Air impact wrench to make short work of the nut, remove inner hub, leaving

The clutch basket which just slides off exposing

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!)

Note the brass screen trapping major metal filings so they don't flow thru the system,

below the oil pump gear

The oil pump drive gear is removed from the clutch basket with a ring pliers

(see the inner hub next to it)

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

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

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)

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 = $4.36

09159-24010 NUT = $5.25

Subtotal: $200.08Shipping: $15.00

Grand Total: $215.08

Here's a detail of the new design clutch basket, "I think I'll call him... Lil' John!"

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

"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

Remove the old clutch hub sleeve and bearing, clean it off well, then lubricate the shaft and the inside of the new sleeve with oil, slip it on

And then slide the old bearing over the new sleeve and lubricate it well

Install the old oil pump drive gear, keyway, and snap ring on the new clutch basket

Slip clutch basket on the clutch hub and wiggle it back and forth to engage

the drive gear, THEN

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

slide the clutch basket all the way back

Slip on thrust bearing washer, and then the inner hub

Slip on the flat washer and the NEW convex washer,

note the orientation of the convex washer

Put on the new clutch hub nut

Tighten hub nut with torque wrench to 108.5 ft-lbs, you will need

the clutch hub holding tool again

Next with chisel and hammer, make a detent on the clutch hub nut

Close up of the clutch hub nut, this sucker ain't going nowhere!

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

Fuzzy picture of last drive plate, goes into OTHER slot

Reinstall clutch push rod, oiled bearings and flat washer

Reinstall pressure plate

And pressure plate spring, hand tightened

Tighten them down in a diagonal fashion, torquing to specs (read the manual)

All done, nicely torqued

Install the new gasket

Note the slot in the upper gear....

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

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

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

says to apply a little grease to the O-ring

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!

Now put all the hoses back to proper places

Install the foot peg, torque to specifications

Refill crankcase with favorite oil

I reused my old coolant since it only had 350 miles on it, and used

new premixed coolant to top off

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

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)

Button everything up, right side fairing, nose piece, AND YOU ARE DONE!