It's been a few days since I have gotten back to this project, but recently I went back to work and it's totally screwed up my moto time. I have taken steps not to deal with that again. I got some better lights for my garage, so now I will be able to work on the bike after work from here on out. That is actually better, I can avoid the angry glares my wife has been giving me for spending so much on parts and tools. I can stay out there until she is into her 3rd cocktail. She's a happy drunk, so I can come into the house on an upswing that way. So, this was the state of the bike last time I worked on it. It's pretty naked these days.
I decided it was time to tear into the engine and start with the fun stuff. I need to change that shift shaft, check the state of the clutch wear parts and take a close look at my clutch booster. If you read the former parts of this rebuild, you will recall that I suspected the clutch booster was the cause of the rattling noise I was hearing at idle and whenever I closed off the throttle. With that oil jet being plugged, I was almost certain that was the problem.
Anyhow, I started by removing the bolts holding the right side engine cover on. This is the cover I need to remove.
I always take a picture to remind me where things like wires are hooked to so I don't forget to put things back together correctly.
There are more than a dozen of the bolts to remove. I loosened everything that looked right and then I removed the clamp and hose from the water pump housing.
Then, using a plastic mallet, I tapped all around the cover to loosen it. After five minutes of this along with wiggling everything, it hadn't budged. So, onto plan B. I removed the clutch cover as well as the water pump housing. I was smart enough to remember my oil pan. Good thing too as there was plenty of coolant and oil to come out as the covers were pulled off. Nice to see the water pump was clean inside. I am not replacing the shaft or seals as the former owner installed a CJ Designs set up that should last many thousands of miles.
After all that was removed, I started wiggle to cover back and forth slowly loosening the old gasket. Eventually, it popped off and I pulled it off to see the insides. I grabbed the clutch basket and checked for play, along with the balancing shaft assemblies. Good news, they were right and tight, no excessive play in any of them.
Then I moved onto the shift shaft, it's that bit with the L shaped plate. It's super simple to remove as well. You compress that spring and it slides right out as easy as can be! That's a huge load off. I like easy and I have grown accustomed to using a shifter when I ride.
From there, it was onto the clutch assembly. I loosened the 6 bolts that hold the pressure plate on. There are springs behind each bolt and they are loosened in a star pattern to keep even tension on the clutch. I gotta say that Clay, the former owner really had those on tight! Dude has some monster pythons for arms.
Removing those bolts and springs allows for the removal of the pressure plate and access to the clutch plates and booster.
Like my fancy work space? That's high quality cardboard. Once removed there was a strong smell of burnt oil as well as sludge on all the parts. More indication of that plugged oil jet I'm sure.
The plates and springs are both wear parts. Over time the springs will compress too much to do their job and the plates will wear down and eventually start slipping. So, out came the micrometer and I took measurements of each plate and spring to check them against specs. After checking each spring, I found that they were all in spec. Unfortunately, the same wasn't true of the fiber plates. They were all at the end of their spec and some of them were worn past spec. I will be replacing those for sure.
Once all the measurements were taken and recorded, it was time to look at that booster. The booster is behind the big 32mm nut. Time to pull out one of my new tools!
My new EBC clutch basket holding tool. I will definitely need it. That clutch nut is on there REALLY tight.
Once the tool is positioned, I can use the breaker bar and my 32mm socket and have at it. The right tool makes everything easier, but in this case not easy. That nut was stubborn!
Once off, that booster assembly pulls right off. Unfortunately, my fears were right. There was a large amount of galling on the booster cams along with an excessive mount of play. Although it is hard to photograph, I did my best job.
This is the booster assembly. It fits together and helps push against the pressure plate.
Well, it wasn't all bad news. I did install my new shift shaft. Once the old one was out, I pulled the new shaft out, oiled it up with some 10w50 and it slid right into place.
Oiled up and ready to go into the engine
Once it was clicked in place, I buttoned up the right side...there was a lot to put back.
Now that that is done, I can get on with this latest order of parts. I have to think it is about the last. I think I have everything else at this point. I ordered an EBC clutch kit as well as a new booster assembly. It will be a week or so before those come in. No worries, I have the time now to replace those coolant hoses as well as check the valve clearances and finally get to those throttle bodies. By then the new parts will be in and I can start getting this moto back together. Dog willing and as long as the creek don't rise. Sorry, I am a slathering John Wayne fan boy.
Well, time to break the news about this latest parts order to my lovely wife, whom I love hope doesn't castrate me in my sleep.
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